Absorbent Articles

ABSTRACT

Absorbent articles having airfelt-free cores or substantially airfelt-free cores in combination with high loft, three-dimensional nonwoven materials are disclosed herein. Packaging comprising the absorbent articles are also disclosed.

RELATED APPLICATIONS

This application claims priority under 35 U.S.C. §119(e) to U.S.Provisional Patent Application Ser. Nos. 62/049,516 (P&G 13530P),62/049,521 (P&G 13531PQ), 62/049,408 (P&G CM4137FPQ), 62/049,406 (P&GCM4136FPQ), 62/049,404 (P&G CM4135FPQ), 62/049,403 (P&G CM4134FPQ),62/049,401 (P&G CM4133FPQ), 62/049,397 (P&G CM4132FPQ), and 62/049,392(P&G CM4131FPQ), all of which were filed on Sep. 12, 2014, and to U.S.Provisional Patent Application Ser. Nos. 62/210,005 (P&G 13971PQ),62/210,014 (P&G13972PQ), 62/210,020 (P&G 13973PQ), and 62/210,057 (P&GCM 4131P2Q), all of which were filed on Aug. 26, 2015. The entiredisclosures of all of the above-referenced U.S. Provisional PatentApplications are fully incorporated herein by reference.

FIELD

The present disclosure relates to absorbent articles, and moreparticularly relates to absorbent articles having substantiallyairfelt-free cores or airfelt-free cores in combination withthree-dimensional nonwoven materials.

BACKGROUND

Absorbent articles are used to absorb and contain bodily exudates (e.g.,urine, menses, BM). The absorbent articles are often configured asdiapers, pants, adult incontinence articles, or sanitary napkins, forexample. Conventional absorbent articles have absorbent cores comprisingsuperabsorbent polymers and cellulosic fibers (for example, sometimes50% or more cellulosic fibers by weight). These conventional absorbentcores provide absorbent articles with thickness and bulk characteristicstypical of an absorbent comprising an assembly of defibered cellulosicfibers. The thickness and bulk of the absorbent articles providesconsumer perceptions of absorbency and performance, while also providingthe absorbent articles with sufficient capillary void volume to managelarge single bodily exudate insults or multiple insults. These absorbentarticles typically have a flat or planar topsheet.

In recent years, one or more absorbent article manufacturers haveproduced absorbent articles comprising absorbent cores with little or nocellulosic fibers. These cores are known as “airfelt-free” cores andtypically comprise superabsorbent polymers and optionally one or morehotmelt adhesives to hold the superabsorbent polymers in position withinthe absorbent core. Some airfelt-free cores rely upon other mechanismsthan hotmelt adhesives, for example mechanical entrapment in pockets, tohold the superabsorbent polymers in position within the absorbent coreduring use. Airfelt-free cores are much thinner than traditionalabsorbent cores in that cellulosic fibers are either not present or arepresent at a very low level by weight within the absorbent cores. Thesethin airfelt-free cores are generally combined with flat or planartopsheets and flat or planer acquisition layers in absorbent articles.As a result, the overall absorbent articles having an airfelt-free coreare much thinner than conventional absorbent articles. The thinness ofthese absorbent articles can lead to the consumer perceptions of lack ofabsorbency and inadequate performance, although this is not technicallyaccurate, since the superabsorbent polymers have sufficient absorbencyand performance attributes. Another issue with the thinness of theabsorbent articles comprising airfelt-free cores is the reduction incapillary void volume within the absorbent articles because of theremoval of all of, or most of, the cellulosic fibers within theabsorbent core. When capillary void volume in an absorbent article isreduced, the absorbent article may be challenged in handling largebodily exudates insults or multiple bodily exudates insults within ashort period of time. Typically, addition of capillary void volumeabsorbent materials to an absorbent article increases the thickness ofthe articles which is a negative for consumers seeking thin, highperformance absorbent articles packaged with low bulk packages. What isneeded are absorbent articles comprising airfelt-free cores thatovercome the above-stated problems.

SUMMARY

The present disclosure solves the problems associated with absorbentarticles comprising airfelt-free cores and planar topsheets by providingabsorbent articles comprising airfelt-free cores and high loft,three-dimensional nonwoven materials. The nonwoven materials may be usedas topsheets or as topsheet/acquisition layer laminates. Unexpectedly,the three-dimensional nonwoven materials of the present disclosureincrease the capillary void volume within the absorbent articlescomprising airfelt-free cores while still preserving the ability to shipthe absorbent articles with a low stack height so as to have lowdistribution costs for the consumer and the manufacturer. This increasein capillary void volume provides the absorbent articles comprisingairfelt-free cores with better ability to receive multiple bodilyexudate insults or large single insults and, thereby, makes theabsorbent articles less prone to leakage. In addition, thethree-dimensional nonwoven materials of the present disclosure, whenused as at least part of a topsheet of an absorbent article, provide theconsumer with an aesthetically pleasing absorbent article with anappearance communicating thickness and absorbency and thus consumerperception of absorbency and performance. The technical performanceimprovements of the absorbent articles of the present disclosure and theconsumer perception improvement accompanying the absorbent articles areunexpectedly realized in combination with the ability to package theabsorbent articles at stack heights where the consumer and themanufacturer also realize distribution conveniences and lower costs.

In a form, the present disclosure is directed, in part, to an absorbentarticle comprises a liquid permeable nonwoven material comprising afirst surface and a second surface. The nonwoven material comprises aplurality of fibers and comprises a generally planar first region and aplurality of discrete integral second regions that comprise deformationsforming protrusions extending outward from the first surface of thenonwoven material and openings in the second surface of the nonwovenmaterial. The protrusions are formed from the fibers. At least some ofthe protrusions comprise a base proximate to the first surface of thenonwoven material, an opposed distal end extending outward in theZ-direction from the base, side walls between the base and the distalend of the protrusion, and a cap comprising at least a portion of theside walls and the distal end of the protrusion. The side walls haveinterior surfaces. Multiple fibers extend from the base of theprotrusion to the distal end of the protrusion, and contribute to form aportion of the sides and cap of the protrusion. The fibers at leastsubstantially surround the sides of the protrusion. The absorbentarticle further comprises a liquid impermeable material and an absorbentcore positioned intermediate the liquid permeable nonwoven material andthe liquid impermeable material. The absorbent core comprises anabsorbent material. The absorbent material comprises at least 85%superabsorbent polymers by weight of the absorbent material.

In a form, the present disclosure is directed, in part, to an absorbentarticle comprises a liquid permeable nonwoven material comprising afirst surface and a second surface. The nonwoven material comprises aplurality of fibers, a generally planar first region and a plurality ofdiscrete integral second regions that comprise deformations formingprotrusions extending outward from the first surface of the nonwovenmaterial and openings in the second surface of the nonwoven material.The protrusions are formed from the fibers. At least some of theprotrusions comprise a base proximate the first surface of the nonwovenmaterial, an opposed distal end extending outward in the Z-directionfrom the base, side walls between the base and the distal end of theprotrusion, and a cap comprising at least a portion of the side wallsand the distal end of the protrusion, wherein the side walls haveinterior surfaces. Multiple fibers extend from the base of theprotrusion to the distal end of the protrusion, and contribute to form aportion of the sides and cap of a protrusion. The interior surfaces ofthe side walls define a base opening at the base of the protrusion. Thecap has a portion with a maximum interior width. The base opening has awidth. The maximum interior width of the cap of the protrusion isgreater than the width of the base opening. The absorbent articlefurther comprising a liquid impermeable material and an absorbent corepositioned intermediate the nonwoven material and the liquid impermeablematerial. The absorbent core comprises an absorbent material. Theabsorbent material comprises at least 85% superabsorbent polymers byweight of the absorbent material and a channel.

In a form, the present disclosure is directed, in part, to a packagecomprises a plurality of absorbent articles. At least some of theabsorbent articles comprise a liquid permeable nonwoven materialcomprising a first surface and a second surface. The nonwoven materialcomprises a plurality of fibers. The nonwoven material comprises agenerally planar first region and a plurality of discrete integralsecond regions that comprise deformations forming protrusions extendingoutward from the first surface of the nonwoven material and openings inthe second surface of the nonwoven material. The protrusions are formedfrom the fibers. At least some of the protrusions comprise a baseproximate the first surface of the nonwoven material, an opposed distalend extending outward in the Z-direction from the base, side wallsbetween the base and the distal end of the protrusion, and a capcomprising at least a portion of the side walls and the distal end ofthe protrusion. The side walls have interior surfaces. Multiple fibersextend from the base of the protrusion to the distal end of theprotrusion, and contribute to form a portion of the sides and cap of aprotrusion. The interior surfaces of the side walls define a baseopening at the base of the protrusion. The cap has a portion with amaximum interior width. The base opening has a width. The maximuminterior width of the cap of the protrusion is greater than the width ofthe base opening. The at least some absorbent articles further comprisea liquid impermeable material and an absorbent core positionedintermediate the liquid permeable nonwoven material and the liquidimpermeable material. The absorbent core comprises an absorbentmaterial. The absorbent material comprises at least 85% superabsorbentpolymers by weight of the absorbent material. The package has an in-bagstack height of less than about 80 mm, according to the In-Back StackHeight Test herein.

In a form, the present disclosure is directed, in part, to an absorbentarticle comprises a liquid pervious nonwoven material having a firstsurface and a second surface. The nonwoven material comprises aplurality of fibers. The nonwoven material comprises a generally planarfirst region and a plurality of discrete integral second regions thatcomprise deformations forming protrusions extending outward from thefirst surface of the nonwoven material and openings in the secondsurface of the nonwoven material. The protrusions are formed from thefibers. At least some of the protrusions have an exterior width, and twoends that define a length of the protrusion therebetween. The at leastsome of the protrusions comprise a base proximate the first surface ofthe nonwoven material, an opposed distal end extending outward in theZ-direction from the base, side walls between the base and the distalend of the protrusion, and a cap comprising at least a portion of theside walls and the distal end of the protrusion. The side walls haveinterior surfaces. The exterior width of the protrusion varies along thelength of the protrusion when the nonwoven material is viewed from thez-direction. The absorbent article further comprises a liquidimpermeable material and an absorbent core positioned intermediate thenonwoven material and the liquid impermeable material. The absorbentcore comprises an absorbent material. The absorbent material comprisesat least 90% superabsorbent polymers by weight of the absorbent materialand a hotmelt adhesive.

In a form, the present disclosure is directed, in part, to an absorbentarticle comprises a liquid pervious nonwoven material having a firstsurface and a second surface. The nonwoven material comprises aplurality of fibers. The nonwoven material comprises a generally planarfirst region and a plurality of discrete integral second regions thatcomprise deformations forming protrusions extending outward from thefirst surface of the nonwoven material and openings in the secondsurface of the nonwoven material. The protrusions are formed from thefibers. At least some of the protrusions have an exterior width, and twoends that define a length of the protrusion therebetween, and the atleast some protrusions comprise a base proximate the first surface ofthe nonwoven material, an opposed distal end extending outward in theZ-direction from the base, side walls between the base and the distalend of the protrusion, and a cap comprising at least a portion of theside walls and the distal end of the protrusion. The side walls haveinterior surfaces. The interior surfaces of the side walls define a baseopening at the base of the protrusion. The cap has a portion with amaximum interior width. The base opening has a width. The maximuminterior width of the cap of the protrusion is greater than the width ofthe base opening. The absorbent article comprises a liquid impermeablematerial and an absorbent core positioned intermediate the nonwovenmaterial and the liquid impermeable material. The absorbent corecomprises an absorbent material. The absorbent material comprises atleast 85% superabsorbent polymers by weight of the absorbent materialand a hotmelt adhesive.

In a form, the present disclosure is directed, in part, to a packagecomprises a plurality of absorbent articles. At least some of theabsorbent articles comprise a liquid pervious nonwoven material having afirst surface and a second surface. The nonwoven material comprises aplurality of fibers. The nonwoven material comprises a generally planarfirst region and a plurality of discrete integral second regions thatcomprise deformations forming protrusions extending outward from thefirst surface of the nonwoven material and openings in the secondsurface of the nonwoven material. The protrusions are formed from thefibers. At least some of the protrusions have an exterior width, and twoends that define a length of the protrusion therebetween. The at leastsome protrusions comprise a base proximate the first surface of thenonwoven material, an opposed distal end extending outward in theZ-direction from the base, side walls between the base and the distalend of the protrusion, and a cap comprising at least a portion of theside walls and the distal end of the protrusion. The side walls haveinterior surfaces. The interior surfaces of the side walls define a baseopening at the base of the protrusion. The cap has a portion with amaximum interior width. The base opening has a width. The maximuminterior width of the cap of the protrusion is greater than the width ofthe base opening. The at least some absorbent articles furthercomprising a liquid impermeable material and an absorbent corepositioned intermediate the liquid permeable nonwoven material and theliquid impermeable material. The absorbent core comprises an absorbentmaterial. The absorbent material comprises at least 85% superabsorbentpolymers by weight of the absorbent material and a hotmelt adhesive. Thepackage has an in-bag stack height of less than about 80 mm, accordingto the In-Back Stack Height Test herein.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features and advantages of the presentdisclosure, and the manner of attaining them, will become more apparentand the disclosure itself will be better understood by reference to thefollowing description of non-limiting embodiments of the disclosuretaken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a photomicrograph showing the end view of a prior art tuff;

FIG. 2 is a schematic end view of a prior art tuft after it has beensubjected to compression;

FIG. 3 is a photomicrograph of the end of a prior art nonwoven webshowing a plurality of collapsed tufts;

FIG. 4 is a schematic side view of a prior art conical-shaped structurebefore and after it has been subjected to compression;

FIG. 5 is a plan view photomicrograph showing one side of a nonwovenmaterial having three-dimensional deformations formed therein, with theprotrusions oriented upward in accordance with the present disclosure;

FIG. 6 is a plan view photomicrograph showing the other side of anonwoven material similar to that shown in FIG. 5, with the openings inthe nonwoven facing upward in accordance with the present disclosure;

FIG. 7 is a Micro CT scan image showing a perspective view of aprotrusion in a single layer nonwoven material in accordance with thepresent disclosure;

FIG. 8 is a Micro CT scan image showing a side of a protrusion in asingle layer nonwoven material in accordance with the presentdisclosure;

FIG. 9 is a Micro CT scan image showing a perspective view of adeformation with the opening facing upward in a single layer nonwovenmaterial in accordance with the present disclosure;

FIG. 10 is a perspective view of a deformation in a two layer nonwovenmaterial with the opening facing upward in accordance with the presentdisclosure;

FIG. 11 is a photomicrograph of a cross-section taken along thetransverse axis of a deformation showing one example of a multi-layernonwoven material having a three-dimensional deformation in the form ofa protrusion on one side of the material that provides a wide opening onthe other side of the material, with the opening facing upward inaccordance with the present disclosure;

FIG. 12 is a schematic view of the protrusion shown in FIG. 11 inaccordance with the present disclosure;

FIG. 13 is a plan view photomicrograph from the protrusion side of amaterial after it has been subjected to compression showing the highfiber concentration region around the perimeter of the protrusion inaccordance with the present disclosure;

FIG. 14 is a photomicrograph of the cross-section of a protrusion takenalong the transverse axis of the protrusion showing the protrusion afterit has been subjected to compression in accordance with the presentdisclosure;

FIG. 15A is a cross-sectional view taken along the transverse axis of adeformation of one embodiment of a multi-layer nonwoven web shown withthe base opening facing upward in accordance with the presentdisclosure;

FIG. 15B is a cross-sectional view taken along the transverse axis of adeformation of an alternative embodiment of a multi-layer nonwoven webshown with the base opening facing upward in accordance with the presentdisclosure;

FIG. 15C is a cross-sectional view taken along the transverse axis of adeformation of an alternative embodiment of a multi-layer nonwoven webshown with the base opening facing upward in accordance with the presentdisclosure;

FIG. 15D is a cross-sectional view taken along the transverse axis of adeformation of an alternative embodiment of a multi-layer nonwoven webshown with the base opening facing upward in accordance with the presentdisclosure;

FIG. 15E is a cross-sectional view taken along the transverse axis of adeformation of an alternative embodiment of a multi-layer nonwoven webshown with the base opening facing upward in accordance with the presentdisclosure;

FIG. 15F is a cross-sectional view taken along the transverse axis of adeformation of an alternative embodiment of a multi-layer nonwoven webshown with the base opening facing upward in accordance with the presentdisclosure;

FIG. 16 is a plan view photomicrograph of a nonwoven web with theprotrusions oriented upward showing the concentration of fibers in onelayer in of a two layer structure in accordance with the presentdisclosure;

FIG. 17 is a perspective view photomicrograph showing the reduced fiberconcentration in the side walls of the protrusions in a layer similar tothat shown in FIG. 16 in accordance with the present disclosure;

FIG. 18 is a plan view photomicrograph of a nonwoven web with theprotrusions oriented upward showing the reduced concentration of fibersin the cap of a protrusion in the other layer of a two layer structurein accordance with the present disclosure;

FIG. 19 is a perspective view photomicrograph showing the increasedfiber concentration in the side walls of the protrusions in a layersimilar to that shown in FIG. 18 in accordance with the presentdisclosure;

FIG. 20 is a perspective view photomicrograph of one layer of a multiplelayer nonwoven material on the surface of a forming roll showing the“hanging chads” that can be formed in one of the layers when somenonwoven precursor web materials are used in accordance with the presentdisclosure;

FIG. 21 is a perspective view of one example of an apparatus for formingthe nonwoven materials described herein in accordance with the presentdisclosure;

FIG. 22 is an enlarged perspective view of a portion of the male rollshown in FIG. 21 in accordance with the present disclosure;

FIG. 23 is an enlarged perspective view showing the nip between therolls shown in FIG. 21 in accordance with the present disclosure;

FIG. 24 is a schematic perspective view of one version of a method ofmaking nonwoven materials having deformations therein where twoprecursor materials are used, one of which is a continuous web and theother of which is in the form of discrete pieces in accordance with thepresent disclosure;

FIG. 25 is an absorbent article in the form of a diaper comprising anexemplary topsheet/acquisition layer composite structure wherein thelength of the acquisition layer is less that the length of the topsheetwith some layers partially removed in accordance with the presentdisclosure;

FIG. 26 is one transverse cross-section of the diaper of FIG. 25 takenalong line 26-26 in accordance with the present disclosure;

FIG. 27 is an alternative transverse cross-section of the diaper of FIG.25 in accordance with the present disclosure;

FIG. 28 is a top view of an example absorbent article, wearer-facingsurface facing the viewer, with some layers partially removed inaccordance with the present disclosure;

FIG. 29 is a cross-sectional view of the absorbent article taken aboutline 29-29 of FIG. 28 in accordance with the present disclosure;

FIG. 30 is a cross-sectional view of the absorbent article taken aboutline 29-29 of FIG. 28 where the absorbent article has been loaded withfluid in accordance with the present disclosure;

FIG. 31 is a top view of another absorbent article, wearer-facingsurface facing the viewer, with some layers partially removed inaccordance with the present disclosure;

FIG. 32 is a cross-sectional view of the absorbent article taken aboutline 32-32 of FIG. 31 in accordance with the present disclosure;

FIG. 33 is a top view of an example absorbent core of the absorbentarticle of FIG. 31 with some layers partially removed in accordance thepresent disclosure;

FIG. 34 is a cross-sectional view of the absorbent core taken about line34-34 of FIG. 33 in accordance with the present disclosure;

FIG. 35 is a cross-sectional view of the absorbent core taken about line35-35 of FIG. 33 in accordance with the present disclosure;

FIG. 36 is a top view of another example absorbent article,wearer-facing surface facing the viewer, that is a sanitary napkin withsome of the layers cut away in accordance with the present disclosure;and

FIG. 37 is a side view of a package of absorbent articles showing thepackage width in accordance with the present disclosure. The outersurface is illustrated as transparent for purposes of clarity.

DETAILED DESCRIPTION

Various non-limiting embodiments of the present disclosure will now bedescribed to provide an overall understanding of the principles of thestructure, function, manufacture, and use of the absorbent articlesdisclosed herein. One or more examples of these non-limiting embodimentsare illustrated in the accompanying drawings. Those of ordinary skill inthe art will understand that the absorbent articles described herein andillustrated in the accompanying drawings are non-limiting exampleembodiments and that the scope of the various non-limiting embodimentsof the present disclosure are defined solely by the claims. The featuresillustrated or described in connection with one non-limiting embodimentmay be combined with the features of other non-limiting embodiments.Such modifications and variations are intended to be included within thescope of the present disclosure.

DEFINITIONS

The term “absorbent article” includes disposable articles such assanitary napkins, panty liners, tampons, interlabial devices, wounddressings, diapers, adult incontinence articles, wipes, and the like. Atleast some of such absorbent articles are intended for the absorption ofbody liquids, such as menses or blood, vaginal discharges, urine, andfeces. Wipes may be used to absorb body liquids, or may be used forother purposes, such as for cleaning surfaces. Various absorbentarticles described above will typically comprise a liquid pervioustopsheet, a liquid impervious backsheet joined to the topsheet, and anabsorbent core between the topsheet and backsheet. The nonwoven materialdescribed herein can comprise at least part of other articles such asscouring pads, wet or dry-mop pads (such as SWIFFER® pads), and thelike.

The term “absorbent core”, as used herein, refers to the component ofthe absorbent article that is primarily responsible for storing liquids.As such, the absorbent core typically does not include the topsheet orbacksheet of the absorbent article.

The term “aperture”, as used herein, refers to a regular orsubstantially regularly-shaped hole that is intentionally formed andextends completely through a web or structure (that is, a through hole).The apertures can either be punched cleanly through the web so that thematerial surrounding the aperture lies in the same plane as the webprior to the formation of the aperture (a “two dimensional” aperture),or the holes can be formed such that at least some of the materialsurrounding the opening is pushed out of the plane of the web. In thelatter case, the apertures may resemble a depression with an aperturetherein, and may be referred to herein as a “three dimensional”aperture, a subset of apertures.

The term “component” of an absorbent article, as used herein, refers toan individual constituent of an absorbent article, such as a topsheet,acquisition layer, liquid handling layer, absorbent core or layers ofabsorbent cores, backsheets, and barriers such as barrier layers andbarrier cuffs.

The term “cross-machine direction” or “CD” means the path that isperpendicular to the machine direction in the plane of the web.

The term “deformable material”, as used herein, is a material which iscapable of changing its shape or density in response to applied stressesor strains.

The term “discrete”, as used herein, means distinct or unconnected. Whenthe term “discrete” is used relative to forming elements on a formingmember, it is meant that the distal (or radially outwardmost) ends ofthe forming elements are distinct or unconnected in all directions,including in the machine and cross-machine directions (even though basesof the forming elements may be formed into the same surface of a roll,for example).

The term “disposable” is used herein to describe absorbent articles andother products which are not intended to be laundered or otherwiserestored or reused as an absorbent article or product (i.e., they areintended to be discarded after use and, preferably, to be recycled,composted or otherwise disposed of in an environmentally compatiblemanner).

The term “forming elements”, as used herein, refers to any elements onthe surface of a forming member that are capable of deforming a web.

The term “integral”, as used herein as in “integral extension” when usedto describe the protrusions, refers to fibers of the protrusions havingoriginated from the fibers of the precursor web(s). Thus, as usedherein, “integral” is to be distinguished from fibers introduced to oradded to a separate precursor web for the purpose of making theprotrusions.

The term “joined to” encompasses configurations in which an element isdirectly secured to another element by affixing the element directly tothe other element; configurations in which the element is indirectlysecured to the other element by affixing the element to intermediatemember(s) which in turn are affixed to the other element; andconfigurations in which one element is integral with another element,i.e., one element is essentially part of the other element. The term“joined to” encompasses configurations in which an element is secured toanother element at selected locations, as well as configurations inwhich an element is completely secured to another element across theentire surface of one of the elements. The term “joined to” includes anyknown manner in which elements can be secured including, but not limitedto mechanical entanglement.

The term “machine direction” or “MD” means the path that material, suchas a web, follows through a manufacturing process.

The term “macroscopic”, as used herein, refers to structural features orelements that are readily visible and distinctly discernable to a humanhaving 20/20 vision when the perpendicular distance between the viewer'seye and the web is about 12 inches (30 cm). Conversely, the term“microscopic” refers to such features that are not readily visible anddistinctly discernable under such conditions.

The term “mechanically deforming”, as used herein, refers to processesin which a mechanical force is exerted upon a material in order topermanently deform the material.

The term “permanently deformed”, as used herein, refers to the state ofa deformable material whose shape or density has been permanentlyaltered in response to applied stresses or strains.

The terms “SELF” and “SELF′ing”, refer to Procter & Gamble technology inwhich SELF stands for Structural Elastic Like Film. While the processwas originally developed for deforming polymer film to have beneficialstructural characteristics, it has been found that the SELF′ing processcan be used to produce beneficial structures in other materials.Processes, apparatuses, and patterns produced via SELF are illustratedand described in U.S. Pat. Nos. 5,518,801; 5,691,035; 5,723,087;5,891,544; 5,916,663; 6,027,483; and 7,527,615 B2.

The term “tuft”, as used herein, refers to a particular type of featurethat may be formed from fibers in a nonwoven web. Tufts may have atunnel-like configuration which may be open at both of their ends.

The term “web” is used herein to refer to a material whose primarydimension is X-Y, i.e., along its length (or longitudinal direction) andwidth (or transverse direction). It should be understood that the term“web” is not necessarily limited to single layers or sheets of material.Thus the web can comprise laminates or combinations of several sheets ofthe requisite type of materials.

The term “Z-dimension” refers to the dimension orthogonal to the lengthand width of the web or article. The Z-dimension usually corresponds tothe thickness of the web or material. As used herein, the term “X-Ydimension” refers to the plane orthogonal to the thickness of the web ormaterial. The X-Y dimension usually corresponds to the length and width,respectively, of the web or material.

Nonwoven Materials

The present disclosure is directed, in part, to high-loft nonwovenmaterials having discrete three-dimensional deformations, whichdeformations provide protrusions on one side of the material, andopenings on the other side of the nonwoven materials. Methods of makingthe nonwoven materials are also disclosed. The nonwoven materials can beused in absorbent articles and other articles, as will be described infurther detail below.

As used herein, the term “nonwoven” refers to a web or material having astructure of individual fibers or threads which are interlaid, but notin a repeating pattern as in a woven or knitted fabric, which lattertypes of fabrics do not typically have randomly oriented orsubstantially randomly-oriented fibers. Nonwoven webs will have amachine direction (MD) and a cross machine direction (CD) as is commonlyknown in the art of web manufacture. By “substantially randomlyoriented” is meant that, due to processing conditions of the precursorweb, there may be a higher amount of fibers oriented in the MD than theCD, or vice versa. For example, in spunbonding and meltblowing processescontinuous strands of fibers are deposited on a support moving in theMD. Despite attempts to make the orientation of the fibers of thespunbond or meltblown nonwoven web truly “random,” usually a slightlyhigher percentage of fibers are oriented in the MD as opposed to the CD.

Nonwoven webs and materials are often incorporated into products, suchas absorbent articles, at high manufacturing line speeds. Suchmanufacturing processes can apply compressive and shear forces on thenonwoven webs that may damage certain types of three-dimensionalfeatures that have been purposefully formed in such webs. In addition,in the event that the nonwoven material is incorporated into a product(such as a disposable diaper) that is made or packaged undercompression, it becomes difficult to preserve the three-dimensionalcharacter of some types of prior three-dimensional features after thematerial is subjected to such compressive forces.

For instance, FIGS. 1 and 2 show an example of a prior art nonwovenmaterial 10 with a tufted structure. The nonwoven material comprisestufts 12 formed from looped fibers 14 that form a tunnel-like structurehaving two ends 16. The tufts 12 extend outward from the plane of thenonwoven material in the Z-direction. The tunnel-like structure has awidth that is substantially the same from one end of the tuft to theopposing end. Often, such tufted structures will have holes or openings18 at both ends and an opening 20 at their base. Typically, the openings18 at the ends of the tufts are at the machine direction (MD) ends ofthe tufts. The openings 18 at the ends of the tufts can be a result ofthe process used to form the tufts. If the tufts 12 are formed byforming elements in the form of teeth with a relatively small tip andvertical leading and trailing edges that form a sharp point, theseleading and/or trailing edges may punch through the nonwoven web atleast one of the ends of the tufts. As a result, openings 18 may beformed at one or both ends of the tufts 12.

While such a nonwoven material 10 provides well-defined tufts 12, theopening 20 at the base of the tuft structure can be relatively narrowand difficult to see with the naked eye. In addition, as shown in FIG.2, the material of the tuft 12 surrounding this narrow base opening 20may tend to form a hinge 22, or pivot point if forces are exerted on thetuft. If the nonwoven is compressed (such as in the Z-direction), inmany cases, the tufts 12 can collapse to one side and close off theopening 20. Typically, a majority of the tufts in such a tufted materialwill collapse and close off the openings 20. FIG. 2 schematically showsan example of a tuft 12 after it has collapsed. In FIG. 2, the tuft 12has folded over to the left side. FIG. 3 is an image showing a nonwovenmaterial with several upwardly-oriented tufts, all of which have foldedover to the side. However, not all of the tufts 12 will collapse andfold over to the same side. Often, some tufts 12 will fold to one side,and some tufts will fold to the other side. As a result of the collapseof the tufts 12, the openings 20 at the base of the tufts can close up,become slit-like, and virtually disappear.

Prior art nonwoven materials with certain other types of threedimensional deformations, such as conical structures, can also besubject to collapse when compressed. As shown in FIG. 4, conicalstructures 24 will not necessarily fold over as will certain tuftedstructures when subjected to compressive forces F. However, conicalstructures 24 can be subject to collapse in that their relatively widebase opening 26 and smaller tip 28 causes the conical structure to pushback toward the plane of the nonwoven material, such as to theconfiguration designated 24A.

The nonwoven materials of at least some embodiments of the presentdisclosure described herein are intended to better preserve thestructure of discrete three-dimensional features in the nonwovenmaterials after compression.

FIGS. 5-14 show examples of nonwoven materials 30 with three-dimensionaldeformations comprising protrusions 32 therein. The nonwoven materials30 have a first surface 34, a second surface 36, and a thickness Ttherebetween (the thickness being shown in FIG. 12). FIG. 5 shows thefirst surface 34 of a nonwoven material 30 with the protrusions 32 thatextend outward from the first surface 34 of the nonwoven materialoriented upward. FIG. 6 shows the second surface 36 of a nonwovenmaterial 30 such as that shown in FIG. 5, having three-dimensionaldeformations formed therein, with the protrusions oriented downward andthe base openings 44 oriented upward. FIG. 7 is a Micro CT scan imageshowing a perspective view of a protrusion 32. FIG. 8 is a Micro CT scanimage showing a side view of a protrusion 32 (of one of the longer sidesof the protrusion). FIG. 9 is a Micro CT scan image showing aperspective view of a deformation with the opening 44 facing upward. Thenonwoven materials 30 comprise a plurality of fibers 38 (shown in FIGS.7-11 and 14). As shown in FIGS. 7 and 9, the nonwoven material 30 mayhave a plurality of bonds 46 therein to hold the fibers 38 together. Anysuch bonds are typically present in the precursor material.

The protrusions 32 may, in some cases, be formed from looped fibers(which may be continuous) 38 that are pushed outward so that they extendout of the plane of the nonwoven web in the Z-direction. The protrusions32 will typically comprise more than one looped fiber. In some cases,the protrusions 32 may be formed from looped fibers and at least somebroken fibers. In addition, in the case of some types of nonwovenmaterials (such as carded materials, which are comprised of shorterfibers), the protrusions 32 may be formed from loops comprising multiplediscontinuous fibers. Multiple discontinuous fibers in the form of aloop are shown as layer 30A in FIGS. 15A-15F. The looped fibers mayeither be aligned (that is, oriented in substantially the samedirection), or not be aligned within the protrusions 32. Typically, ifmale/female forming elements are used to form the protrusions, and thefemale forming elements substantially surround the male formingelements, the fibers in the protrusions 32 may remain substantiallyrandomly oriented (rather than aligned), similar to their orientation inthe precursor web(s) from which the nonwoven materials 30 are formed.

The nonwoven material 30 may comprise a generally planar first region 40and the three-dimensional deformations may comprise a plurality ofdiscrete integral second regions 42. The term “generally planar” is notmeant to imply any particular flatness, smoothness, or dimensionality.Thus, the first region 40 can include other features that provide thefirst region 40 with a topography. Such other features can include, butare not limited to small projections, raised network regions around thebase openings 44, and other types of features. Thus, the first region 40is generally planar when considered relative to the second regions 42.

The term “deformation”, as used herein, includes both the protrusions 32formed on one side of the nonwoven material and the base openings 44formed in the opposing side of the material. The base openings 44 aremost often not in the form of an aperture or a through-hole. The baseopenings 44 may instead appear as depressions. The base openings 44 canbe analogized to the opening of a bag. A bag has an opening thattypically does not pass completely through the bag. In the case of thepresent nonwoven materials 30, as shown in FIG. 10, the base openings 44open into the interior of the protrusions 32.

FIG. 11 shows one example of a multi-layer nonwoven material 30 having athree-dimensional deformation in the form of a protrusion 32 on one sideof the material that provides a wide base opening 44 on the other sideof the material. The dimensions of “wide” base openings are described infurther detail below. In this case, the base opening 44 is orientedupward in the figure. When there is more than one nonwoven layer, theindividual layers can be designated 30A, 30B, etc. The individual layers30A and 30B each have first and second surfaces, which can be designatedsimilarly to the first and second surfaces 34 and 36 of the nonwovenmaterial (e.g., 34A and 36A for the first and second surfaces of thefirst layer 30A; and, 34B and 36B for the first and second surfaces ofthe second layer 30B).

As shown in FIGS. 11 and 12, the protrusions 32 comprise: a base 50proximate the first surface 34 of the nonwoven material; an opposedenlarged distal portion or cap portion, or “cap” 52, that extends to adistal end 54; side walls (or “sides”) 56; an interior 58; and a pair ofends 60 (the latter being shown in FIG. 5). The “base” 50 of theprotrusions 32 comprises the narrowest portion of the protrusion whenviewed from one of the ends of the protrusion. The term “cap” does notimply any particular shape, other than it comprises the wider portion ofthe protrusion 32 that includes and is adjacent to the distal end 54 ofthe protrusion 32. The side walls 56 have an inside surface 56A and anoutside surface 56B. As shown in FIGS. 11 and 12, the side walls 56transition into, and may comprise part of the cap 52. Therefore, it isnot necessary to precisely define where the side walls 56 end and thecap 52 begins. The cap 52 will have a maximum interior width, W_(I),between the inside surfaces 56A of the opposing side walls 56. The cap52 will also have a maximum exterior width W between the outsidesurfaces 56B of the opposing side walls 56. The ends 60 of theprotrusions 32 are the portions of the protrusions that are spacedfurthest apart along the longitudinal axis, L, of the protrusions.

As shown in FIGS. 11 and 12, the narrowest portion of the protrusion 32defines the base opening 44. The base opening 44 has a width W_(O). Thebase opening 44 may be located (in the z-direction) between the planedefined by the second surface 36 of the material and the distal end 54of the protrusion. As shown in FIGS. 11 and 12, the nonwoven material 30may have an opening in the second surface 36 (the “second surfaceopening” 64) that transitions into the base opening 44 (and vice versa),and is the same size as, or larger than the base opening 44. The baseopening 44 will, however, generally be discussed more frequently hereinsince its size will often be more visually apparent to the consumer inthose embodiments where the nonwoven material 30 is placed in an articlewith the base openings 44 visible to the consumer. It should beunderstood that in certain embodiments, such as in embodiments in whichthe base openings 44 face outward (for example, toward a consumer andaway from the absorbent core in an absorbent article), it may bedesirable for the base openings 44 not to be covered and/or closed offby another web.

As shown in FIG. 12, the protrusions 32 have a depth D measured from thesecond surface 36 of the nonwoven web to the interior of the protrusionat the distal end 54 of the protrusions. The protrusions 32 have aheight H measured from the second surface 36 of the nonwoven web to thedistal end 54 of the protrusions. In most cases the height H of theprotrusions 32 will be greater than the thickness T of the first region40. The relationship between the various portions of the deformationsmay be such that as shown in FIG. 11, when viewed from the end, themaximum interior width W_(I) of the cap 52 of the protrusions is widerthan the width, W_(O), of the base opening 44.

The protrusions 32 may be of any suitable shape. Since the protrusions32 are three-dimensional, describing their shape depends on the anglefrom which they are viewed. When viewed from above (that is,perpendicular to the plane of the web, or plan view) such as in FIG. 5,suitable shapes include, but are not limited to: circular,diamond-shaped, rounded diamond-shaped, U.S. football-shaped,oval-shaped, clover-shaped, triangle-shaped, tear-drop shaped, andelliptical-shaped. (The base openings 44 will typically have a shapesimilar to the plan view shape of the protrusions 32.) In other cases,the protrusions 32 (and base openings 44) may be non-circular. Theprotrusions 32 may have similar plan view dimensions in all directions,or the protrusions may be longer in one dimension than another. That is,the protrusions 32 may have different length and width dimensions. Ifthe protrusions 32 have a different length than width, the longerdimension will be referred to as the length of the protrusions. Theprotrusions 32 may, thus, have a ratio of length to width, or an aspectratio. The aspect ratios can range from about 1:1 to about 10:1.

As shown in FIG. 5, the protrusions 32 may have a width, W, that variesfrom one end 60 to the opposing end 60 when the protrusions are viewedin plan view. The width W may vary with the widest portion of theprotrusions in the middle of the protrusions, and the width of theprotrusions decreasing at the ends 60 of the protrusions. In othercases, the protrusions 32 could be wider at one or both ends 60 than inthe middle of the protrusions. If the width of the protrusions 32 variesalong the length of the protrusions, the portion of the protrusion wherethe width is the greatest is used in determining the aspect ratio of theprotrusions.

When the protrusions 32 have a length L that is greater than their widthW, the length of the protrusions may be oriented in any suitabledirection relative to the nonwoven material 30. For example, the lengthof the protrusions 32 (that is, the longitudinal axis, LA, of theprotrusions) may be oriented in the machine direction, the cross-machinedirection, or any desired orientation between the machine direction andthe cross-machine direction. The protrusions 32 also have a transverseaxis TA generally orthogonal to the longitudinal axis LA in the MD-CDplane. In the embodiment shown in FIGS. 5 and 6, the longitudinal axisLA is parallel to the MD. In some embodiments, all the spaced apartprotrusions 32 may have generally parallel longitudinal axes LA.

The protrusions 32 may have any suitable shape when viewed from theside. Suitable shapes include those in which there is a distal portionor “cap” with an enlarged dimension and a narrower portion at the basewhen viewed from at least one side. The term “cap” is analogous to thecap portion of a mushroom. (The cap does not need to resemble that ofany particular type of mushroom. In addition, the protrusions 32 may,but need not, have a mushroom-like stem portion.) In some cases, theprotrusions 32 may be referred to as having a bulbous shape when viewedfrom the end 60, such as in FIG. 11. The term “bulbous”, as used herein,is intended to refer to the configuration of the protrusions 32 ashaving a cap 52 with an enlarged dimension and a narrower portion at thebase when viewed from at least one side (particularly when viewing fromone of the shorter ends 60) of the protrusion 32. The term “bulbous” isnot limited to protrusions that have a circular or round plan viewconfiguration that is joined to a columnar portion. The bulbous shape,in the embodiment shown (where the longitudinal axis LA of thedeformations 32 is oriented in the machine direction), may be mostapparent if a section is taken along the transverse axis TA of thedeformation (that is, in the cross-machine direction). The bulbous shapemay be less apparent if the deformation is viewed along the length (orlongitudinal axis LA) of the deformation such as in FIG. 8.

The protrusions 32 may comprise fibers 38 that at least substantiallysurround the sides of the protrusions. This means that there aremultiple fibers that extend (e.g., in the Z-direction) from the base 50of the protrusions 32 to the distal end 54 of the protrusions, andcontribute to form a portion of the sides 56 and cap 52 of a protrusion.The phrase “substantially surround” does not require that eachindividual fiber be wrapped in the X-Y plane substantially or completelyaround the sides of the protrusions. If the fibers 38 are locatedcompletely around the sides of the protrusions, this would mean that thefibers are located 360° around the protrusions. The protrusions 32 maybe free of large openings at their ends 60, such as those openings 18 atthe leading end and trailing end of the tufts shown in FIG. 1. Theprotrusions 32 also differ from embossed structures such as shown inFIG. 4. Embossed structures typically do not have distal portions thatare spaced perpendicularly away (that is, in the Z-direction) from theirbase that are wider than portions that are adjacent to their base, as inthe case of the cap 52 on the present protrusions 32.

The protrusions 32 may have certain additional characteristics. As shownin FIGS. 11 and 12, the protrusions 32 may be substantially hollow. Asused herein, the term “substantially hollow” refers to structures whichthe protrusions 32 are substantially free of fibers in interior ofprotrusions. The term “substantially hollow”, does not, however, requirethat the interior of the protrusions must be completely free of fibers.Thus, there can be some fibers inside the protrusions. “Substantiallyhollow” protrusions are distinguishable from filled three-dimensionalstructures, such as those made by laying down fibers, such as byairlaying or carding fibers onto a forming structure with recessestherein.

The side walls 56 of the protrusions 32 can have any suitableconfiguration. The configuration of the side walls 56, when viewed fromthe end of the protrusion such as in FIG. 11, can be linear orcurvilinear, or the side walls can be formed by a combination of linearand curvilinear portions. The curvilinear portions can be concave,convex, or combinations of both. For example, the side walls 56 in theembodiment show in FIG. 11, comprise portions that are curvilinearconcave inwardly near the base of the protrusions and convex outwardlynear the cap of the protrusions. The sidewalls 56 and the area aroundthe base opening 44 of the protrusions may, under 20× magnification,have a visibly significantly lower concentration of fibers per givenarea (which may be evidence of a lower basis weight or lower opacity)than the portions of the nonwoven in the unformed first region 40. Theprotrusions 32 may also have thinned fibers in the sidewalls 56. Thefiber thinning, if present, will be apparent in the form of neckedregions in the fibers 38 as seen in scanning electron microscope (SEM)images taken at 200× magnification. Thus, the fibers may have a firstcross-sectional area when they are in the undeformed nonwoven precursorweb, and a second cross-sectional area in the side walls 56 of theprotrusions 32 of the deformed nonwoven web, wherein the firstcross-sectional area is greater than the second cross-sectional area.The side walls 56 may also comprise some broken fibers as well.

In some embodiments, the distal end 54 of the protrusions 32 may becomprised of original basis weight, non-thinned, and non-broken fibers.If the base opening 44 faces upward, the distal end 54 will be at thebottom of the depression that is formed by the protrusion. The distalend 54 will be free from apertures formed completely through the distalend. Thus, the nonwoven materials may be nonapertured. The term“apertures”, as used herein, refers to holes formed in the nonwovensafter the formation of the nonwovens, and does not include the porestypically present in nonwovens. The term “apertures” also does not referto irregular breaks (or interruptions) in the nonwoven material(s) suchas shown in FIGS. 15D-15F and FIG. 20 resulting from localized tearingof the material(s) during the process of forming deformations therein,which breaks may be due to variability in the precursor material(s). Thedistal end 54 may have relatively greater fiber concentration or densityin comparison to the remaining portions of the structure that forms theprotrusions. As described in greater detail below, however, if thenonwoven web is comprised of more than one layer, the concentration offibers in the different portions of the protrusions may vary between thedifferent layers.

The protrusions 32 may be of any suitable size. The size of theprotrusions 32 can be described in terms of protrusion length, width,caliper, height, depth, cap size, and opening size. (Unless otherwisestated, the length L and width W of the protrusions are the exteriorlength and width of the cap 52 of the protrusions.) The dimensions ofthe protrusions and openings can be measured before and aftercompression (under either a pressure of 7 kPa or 35 KPa, whichever isspecified) in accordance with the Accelerated Compression Methoddescribed in the Test Methods section. The protrusions have a caliperthat is measured between the same points as the height H, but under a 2KPa load, in accordance with the Accelerated Compression Method. Alldimensions of the protrusions and openings other than caliper (that is,length, width, height, depth, cap size, and opening size) are measuredwithout pressure applied at the time of making the measurement using amicroscope at 20× magnification.

In some embodiments, the length of the cap 52 may be in a range fromabout 1.5 mm to about 10 mm. In some embodiments, the width of the cap(measured where the width is the greatest) may be in a range from about1.5 mm to about 5 mm. The cap portion of the protrusions may have a planview surface area of at least about 3 mm². In some embodiments, theprotrusions may have a pre-compression height H that is in a range fromabout 1 mm to about 10 mm, alternatively from about 1 mm to about 6 mm.In some embodiments, the protrusions may have a post-compression heightH that is in a range from about 0.5 mm to about 6 mm, alternatively fromabout 0.5 mm to about 1.5 mm. In some embodiments, the protrusions mayhave a depth D, in an uncompressed state that is in a range from about0.5 mm to about 9 mm, alternatively from about 0.5 mm to about 5 mm. Insome embodiments, the protrusions may have a depth D, after compressionthat is in a range from about 0.25 mm to about 5 mm, alternatively fromabout 0.25 mm to about 1 mm.

The nonwoven material 30 can comprise a composite of two or morenonwoven materials that are joined together. In such a case, the fibersand properties of the first layer will be designated accordingly (e.g.,the first layer is comprised of a first plurality of fibers), and thefibers and properties of the second and subsequent layers will bedesignated accordingly (e.g., the second layer is comprised of a secondplurality of fibers). In a two or more layer structure, there are anumber of possible configurations the layers may take following theformation of the deformations therein. These will often depend on theextensibility of the nonwoven materials used for the layers. It isdesirable that at least one of the layers have deformations which formprotrusions 32 as described herein in which, along at least onecross-section, the width of the cap 52 of the protrusions is greaterthan the width of the base opening 44 of the deformations. For example,in a two layer structure where one of the layers will serve as thetopsheet of an absorbent article and the other layer will serve as anunderlying layer (such as an acquisition layer), the layer that hasprotrusions therein may comprise the topsheet layer. The layer that mosttypically has a bulbous shape will be the one which is in contact withthe male forming member during the process of deforming the web. FIG.15A-FIG. 15E show different alternative embodiments of three-dimensionalprotrusions 32 in multiple layer materials.

In certain embodiments, such as shown in FIGS. 11, 12, and 15A,similar-shaped looped fibers may be formed in each layer of multiplelayer nonwoven materials, including in the layer 30A that is spacedfurthest from the discrete male forming elements during the process offorming the protrusions therein, and in the layer 30B that is closest tothe male forming elements during the process. One layer such as 30B fitswithin the other layer, such as 30A. These layers may be referred to asa “nested” structure. Formation of a nested structure may require theuse of two (or more) highly extensible nonwoven precursor webs. In thecase of two layer materials, nested structures may form two completeloops, or (as shown in some of the following drawing figures) twoincomplete loops of fibers.

As shown in FIG. 15A, a three-dimensional protrusion 32 comprisesprotrusions 32A formed in the first layer 30A and protrusions 32B formedin the second layer 30B. In one embodiment, the first layer 30A may beincorporated into an absorbent article as an acquisition layer, and thesecond layer 30B may be a topsheet, and the protrusions formed by thetwo layers may fit together (that is, are nested). In this embodiment,the protrusions 32A and 32B formed by the first and second layers 30Aand 30B fit closely together. The three-dimensional protrusion 32Acomprises a plurality of fibers 38A and the three-dimensional protrusion32B comprises a plurality of fibers 38B. The three-dimensionalprotrusion 32B is nested into the three-dimensional protrusion 32A. Inthe embodiment shown, the fibers 38A in the first layer 30A are shorterin length than the fibers 38B in the second layer 30B. In otherembodiments, the relative length of fibers in the layers may be thesame, or in the opposite relationship wherein the fibers in the firstlayer are longer than those in the second layer. In addition, in thisembodiment, and any of the other embodiments described herein, thenonwoven layers can be inverted when incorporated into an absorbentarticle, or other article, so that the protrusions 32 face upward (oroutward). In such a case, the material suitable for the topsheet will beused in layer 30A, and material suitable for the underlying layer willbe used in layer 30B.

FIG. 15B shows that the nonwoven layers need not be in a contactingrelationship within the entirety of the protrusion 32. Thus, theprotrusions 32A and 32B formed by the first and second layers 30A and30B may have different heights and/or widths. The two materials may havesubstantially the same shape in the protrusion 32 as shown in FIG. 15B(where one of the materials has the same the curvature as the other). Inother embodiments, however, the layers may have different shapes. Itshould be understood that FIG. 15B shows only one possible arrangementof layers, and that many other variations are possible, but that as inthe case of all the figures, it is not possible to provide a drawing ofevery possible variation.

As shown in FIG. 15C, one of the layers, such as first layer 30A (e.g.,an acquisition layer) may be ruptured in the area of thethree-dimensional protrusion 32. As shown in FIG. 15C, the protrusions32 are only formed in the second layer 30B (e.g., the topsheet) andextend through openings in the first layer 30A. That is, thethree-dimensional protrusion 32B in the second layer 30B interpenetratesthe ruptured first layer 30A. Such a structure may place the topsheet indirect contact an underlying distribution layer or absorbent core, whichmay lead to improved dryness. In such an embodiment, the layers are notconsidered to be “nested” in the area of the protrusion. (In the otherembodiments shown in FIGS. 15D-15F, the layers would still be consideredto be “nested”.) Such a structure may be formed if the material of thesecond layer 30B is much more extensible than the material of the firstlayer 30A. In such a case, the openings can be formed by locallyrupturing first precursor web by the process described in detail below.The ruptured layer may have any suitable configuration in the area ofthe protrusion 32. Rupture may involve a simple splitting open of firstprecursor web, such that the opening in the first layer 30A remains asimple two-dimensional aperture. However, for some materials, portionsof the first layer 30A can be deflected or urged out-of-plane (i.e., outof the plane of the first layer 30A) to form flaps 70. The form andstructure of any flaps is highly dependent upon the material propertiesof the first layer 30A. Flaps can have the general structure shown inFIG. 15C. In other embodiments, the flaps 70 can have a morevolcano-like structure, as if the protrusion 32B is erupting from theflaps.

Alternatively, as shown in FIGS. 15D-15F, one or both of the first layer30A and the second layer 30B may be interrupted (or have a breaktherein) in the area of the three-dimensional protrusion 32. FIGS. 15Dand 15E show that the three-dimensional protrusion 32A of the firstlayer 30A may have an interruption 72A therein. The three-dimensionalprotrusion 32B of the non-interrupted second layer 30B may coincide withand fit together with the three-dimensional protrusion 32A of theinterrupted first layer 30A. Alternatively, FIG. 15F shows an embodimentin which both the first and second layers 30A and 30B haveinterruptions, or breaks, therein (72A and 72B, respectively). In thiscase, the interruptions in the layers 30A and 30B are in differentlocations in the protrusion 32. FIGS. 15D-15F show unintentional randomor inconsistent breaks in the materials typically formed by random fiberbreakage, which are generally misaligned and can be in the first orsecond layer, but are not typically aligned and completely through bothlayers. Thus, there typically will not be an aperture formed completelythrough all of the layers at the distal end 54 of the protrusions 32.

For dual layer and other multiple layer structures, the basis weightdistribution (concentration of fibers) within the deformed material 30can be different between the layers. As shown in FIG. 16, the nonwovenlayer in contact with the male forming element (e.g., 30B) may have alarge portion at the distal end 54B of the protrusion 32B with a similarbasis weight to the original nonwoven. As shown in FIG. 17, the basisweight in the sidewalls 56B of the protrusion 32B and near the baseopening 44 may be lower than the basis weight of the original materialand the distal end 54 of the protrusion 32B. As shown in FIG. 18, thenonwoven layer in contact with the female forming element (e.g., 30A)may, however, have significantly less basis weight in the cap 52A of theprotrusion 32A than in the original nonwoven. As shown in FIG. 19, thesidewalls 56A of the protrusion 32A may have less basis weight than theoriginal nonwoven, but more basis weight than the distal end 54A of theprotrusion 32A.

The base openings 44 can be of any suitable shape and size. The shape ofthe base opening 44 will typically be similar to, or the same as, theplan view shape of the corresponding protrusions 32. The base opening 44may have a width that is greater than about any of the followingdimensions before (and after compression): 0.5 mm, 0.7 mm, 0.8 mm, 0.9mm, 1 mm, or any 0.1 mm increment above 1 mm. The width of the baseopening 44 may be in a range that is from any of the foregoing amountsup to about 4 mm, or more. The base openings 44 may have a length thatranges from about 1.5 mm or less to about 10 mm, or more. The baseopenings 44 may have an aspect ratio that ranges from about 1:1 to 20:1,alternatively from about 1:1 to 10:1. Measurements of the dimensions ofthe base opening can be made on a photomicrograph. When the size of thewidth of the base opening 44 is specified herein, it will be appreciatedthat if the openings are not of uniform width in a particular direction,the width, W_(O), is measured at the widest portion as shown in FIG. 6.The nonwoven materials of the present disclosure and the method ofmaking the same may create deformations with a wider opening thancertain prior structures which have a narrow base. This allows the baseopenings 44 to be more visible to the naked eye. The width of the baseopening 44 is of interest because, being the narrowest portion of theopening, it will be most restrictive of the size of the opening. Thedeformations retain their wide base openings 44 after compressionperpendicular to the plane of the first region 40.

The deformations may compress under load. In some cases, it may bedesirable that the load is low enough so that, if the nonwoven is wornagainst a wearer's body, with the deformations in contact with thewearer's body, the deformations will be soft and will not imprint theskin. This applies in cases where either the protrusions 32 or the baseopenings 44 are oriented so that they are in contact with the wearer'sbody. For example, it may be desirable for the deformations to compressunder pressures of 2 kPa or less. In other cases, it will not matter ifthe deformations imprint the wearer's skin. It may be desirable for atleast one of the protrusions 32 in the nonwoven material 30 to collapseor buckle in the controlled manner described below under the 7 KPa loadwhen tested in accordance with the Accelerated Compression Method in theTest Methods section below. Alternatively, at least some, or in othercases, a majority of the protrusions 32 may collapse in the controlledmanner described herein. Alternatively, substantially all of theprotrusions 32 may collapse in the controlled manner described herein.The ability of the protrusions 32 to collapse may also be measured undera load of 35 kPa. The 7 kPa and 35 kPa loads simulate manufacturing andcompression packaging conditions. Wear conditions can range from no orlimited pressure (if the wearer is not sitting on the absorbent article)up to 2 kPa, 7 kPa, or more.

The protrusions 32 may collapse in a controlled manner after compressionto maintain the wide opening 44 at the base. FIG. 13 shows the firstsurface 34 of a nonwoven material 30 according to the present disclosureafter it has been subjected to compression. FIG. 14 is a side view of asingle downwardly-oriented protrusion 32 after it has been subjected tocompression. As shown in FIG. 13, when the protrusions 32 have beencompressed, there appears to be a higher concentration of fibers in theform of a ring of increased opacity 80 around the base opening 44. Whena compressive force is applied to the nonwoven materials, the side walls56 of the protrusions 32 may collapse in a more desirable/controlledmanner such that the side walls 56 become concave and fold into regionsof overlapping layers (such as into an s-shape/accordion-shape). Thering of increased opacity 80 represents folded layers of material. Inother words, the protrusions 32 may have a degree of dimensionalstability in the X-Y plane when a Z-direction force is applied to theprotrusions. It is not necessary that the collapsed configuration of theprotrusions 32 be symmetrical, only that the collapsed configurationprevent the protrusions 32 from flopping over or pushing back into theoriginal plane of the nonwoven, and significantly reducing the size ofthe base opening. For example, as shown in FIG. 14, the left side of theprotrusion 32 can form a z-folded structure, and the right side of theprotrusion does not, but still appears, when viewed from above, to havehigher opacity due to a degree of overlapping of the material in thefolded portion. Without wishing to be bound to any particular theory, itis believed that the wide base opening 44 and large cap 52 (greater thanthe width of the base opening 44), combined with the lack of a pivotpoint, causes the protrusions 32 to collapse in a controlled manner(prevents the protrusion 32 from flopping over). Thus, the protrusions32 are free of a hinge structure that would otherwise permit them tofold to the side when compressed. The large cap 52 also prevents theprotrusion 32 from pushing back into the original plane of the nonwoven.

The deformations can be disposed in any suitable density across thesurface of the nonwoven material 30. The deformations may, for example,be present in a density of: from about 5 to about 100 deformations;alternatively from about 10 to about 50 deformations; alternatively fromabout 20 to about 40 deformations, in an area of 10 cm².

The deformations can be disposed in any suitable arrangement across theplane of the nonwoven material. Suitable arrangements include, but arenot limited to: staggered arrangements, and zones. In some cases, thenonwoven material 30 may comprise both deformations and other featuresknown in the art such as embossments and apertures. The deformations andother features may be in separate zones, be intermixed, or overlap.Intermixed arrangements can be created in any suitable manner. In somecases, intermixed arrangements can be created by using the techniquesdescribed in U.S. Patent Publication No. US 2012/0064298 A1, Orr, et al.In other cases, overlapping arrangements can be created by forming thedeformations and then subsequently passing the nonwoven web between aforming member having male forming elements thereon and a compliantsurface, and applying pressure to the web with the forming member andcompliant surface. These techniques for producing overlappingarrangements enable deformations and other features to be combined sothey are disposed in different locations on the nonwoven material orthey can cause at least some of the deformations and at least some ofthe other features to be disposed in the same location on the nonwovenmaterial.

The nonwoven webs 30 described herein can comprise any suitablecomponent or components of an absorbent article. For example, thenonwoven webs can comprise the topsheet of an absorbent article, or asshown in FIG. 25, if the nonwoven web 30 comprises more than one layer,the nonwoven web can comprise a combined topsheet 84 and acquisitionlayer 86 of an absorbent article, such as diaper 82. The diaper 82 shownin FIGS. 25-27 also comprises an absorbent core 88, a backsheet 94, anda distribution layer 96. The nonwoven materials of the presentdisclosure may also form an outer cover of an absorbent article, such asbacksheet 94. The nonwoven webs 30 can be placed in an absorbent articlewith the deformations 31 in any suitable orientation. For example, theprotrusions 32 can be oriented up or down. In other words, theprotrusions 32 may be oriented toward the absorbent core 88 as shown inFIG. 26. Thus, for example, it may be desirable for the protrusions 32to point inward toward the absorbent core 88 in a diaper (that is, awayfrom the body-facing side and toward the garment-facing side), or otherabsorbent article. Alternatively, the protrusions 32 may be oriented sothat they extend away from the absorbent core of the absorbent articleas shown in FIG. 27. In still other embodiments, the nonwoven webs 30can be made so that they have some protrusions 32 that are orientedupward, and some that are oriented downward. Without wishing to be boundto any particular theory, it is believed that such a structure may beuseful in that the protrusions that are oriented upward can be moreeffective for cleaning the body from exudates, while the protrusionsthat are oriented downward can be more effective for absorption ofexudates into the absorbent core. Therefore, without being bound totheory, a combination of these two protrusion orientations will offeradvantage that the same product can fulfill the two functions.

A two or more layer nonwoven structure may provide fluid handlingbenefits. If the layers are integrated together, and the protrusions 32are oriented toward the absorbent core, they may also provide a drynessbenefit. It may be desirable, on the other hand, for the protrusions 32to point outward, away from the absorbent core in a pad for a wet or drymop to provide a cleaning benefit. In some embodiments, when thenonwoven web 30 is incorporated into an absorbent article, theunderlying layers can be either substantially, or completely free, oftow fibers. Suitable underlying layers that are free of tow fibers may,for example, comprise a layer or patch of cross-linked cellulose fibers.In some cases, it may be desirable that the nonwoven material 30 is notentangled with (that is, is free from entanglement with) another web.

The layers of the nonwoven structure (e.g., a topsheet and/oracquisition layer) may be colored. Color may be imparted to the webs bycolor pigmentation. The term “color pigmentation” encompasses anypigments suitable for imparting a non-white color to a web. This termtherefore does not include “white” pigments such as TiO₂ which aretypically added to the layers of conventional absorbent articles toimpart them with a white appearance. Pigments are usually dispersed invehicles or substrates for application, as for instance in inks, paints,plastics or other polymeric materials. The pigments may for example beintroduced in a polypropylene masterbatch. A masterbatch comprises ahigh concentration of pigment and/or additives which are dispersed in acarrier medium which can then be used to pigment or modify the virginpolymer material into a pigmented bicomponent nonwoven. An example ofsuitable colored masterbatch material that can be introduced is Pantonecolor 270 Sanylen violet PP 42000634 ex Clariant, which is a PP resinwith a high concentration of violet pigment. Typically, the amount ofpigments introduced by weight of the webs may be of from 0.3%-2.5%.Alternatively, color may be imparted to the webs by way of impregnationof a colorant into the substrate. Colorants such as dyes, pigments, orcombinations may be impregnated in the formation of substrates such aspolymers, resins, or nonwovens. For example, the colorant may be addedto molten batch of polymer during fiber or filament formation.

Precursor Materials.

The nonwoven materials of the present disclosure can be made of anysuitable nonwoven materials (“precursor materials”). The nonwoven webscan be made from a single layer, or multiple layers (e.g., two or morelayers). If multiple layers are used, they can be comprised of the sametype of nonwoven material, or different types of nonwoven materials. Insome cases, the precursor materials may be free of any film layers.

The fibers of the nonwoven precursor material(s) can be made of anysuitable materials including, but not limited to natural materials,synthetic materials, and combinations thereof. Suitable naturalmaterials include, but are not limited to cellulose, cotton linters,bagasse, wool fibers, silk fibers, etc. Cellulose fibers can be providedin any suitable form, including but not limited to individual fibers,fluff pulp, drylap, liner board, etc. Suitable synthetic materialsinclude, but are not limited to nylon, rayon and polymeric materials.Suitable polymeric materials include, but are not limited to:polyethylene (PE), polyester, polyethylene terephthalate (PET),polypropylene (PP), and co-polyester. In some embodiments, however, thenonwoven precursor materials can be either substantially, or completelyfree, of one or more of these materials. For example, in someembodiments, the precursor materials may be substantially free ofcellulose, and/or exclude paper materials. In some embodiments, one ormore precursor materials can comprise up to 100% thermoplastic fibers.The fibers in some cases may, therefore, be substantially non-absorbent.In some embodiments, the nonwoven precursor materials can be eithersubstantially, or completely free, of tow fibers.

The precursor nonwoven materials can comprise any suitable types offibers. Suitable types of fibers include, but are not limited to:monocomponent, bicomponent, and/or biconstituent, non-round (e.g.,shaped fibers (including but not limited to fibers having a trilobalcross-section) and capillary channel fibers). The fibers can be of anysuitable size. The fibers may, for example, have major cross-sectionaldimensions (e.g., diameter for round fibers) ranging from 0.1-500microns. Fiber size can also be expressed in denier, which is a unit ofweight per length of fiber. The constituent fibers may, for example,range from about 0.1 denier to about 100 denier. The constituent fibersof the nonwoven precursor web(s) may also be a mixture of differentfiber types, differing in such features as chemistry (e.g., PE and PP),components (mono- and bi-), shape (i.e. capillary channel and round) andthe like.

The nonwoven precursor webs can be formed from many processes, such as,for example, air laying processes, wetlaid processes, meltblowingprocesses, spunbonding processes, and carding processes. The fibers inthe webs can then be bonded via spunlacing processes, hydroentangling,calendar bonding, through-air bonding and resin bonding. Some of suchindividual nonwoven webs may have bond sites where the fibers are bondedtogether.

The basis weight of nonwoven materials is usually expressed in grams persquare meter (gsm). The basis weight of a single layer nonwoven materialcan range from about 8 gsm to about 100 gsm, depending on the ultimateuse of the material 30. For example, the topsheet of atopsheet/acquisition layer laminate or composite may have a basis weightfrom about 8 to about 40 gsm or from about 8 to about 30 gsm, or fromabout 8 to about 20 gsm. The acquisition layer may have a basis weightfrom about 10 to about 120 gsm or from about 10 to about 100 gsm, orfrom about 10 to about 80 gsm. The basis weight of a multi-layermaterial is the combined basis weight of the constituent layers and anyother added components. The basis weight of multi-layer materials ofinterest herein can range from about 20 gsm to about 150 gsm, dependingon the ultimate use of the material 30. The nonwoven precursor webs mayhave a density that is between about 0.01 and about 0.4 g/cm³ measuredat 0.3 psi (2 KPa).

The precursor nonwoven webs may have certain desired characteristics.The precursor nonwoven web(s) each have a first surface, a secondsurface, and a thickness. The first and second surfaces of the precursornonwoven web(s) may be generally planar. It is typically desirable forthe precursor nonwoven web materials to have extensibility to enable thefibers to stretch and/or rearrange into the form of the protrusions. Ifthe nonwoven webs are comprised of two or more layers, it is desirablefor all of the layers to be as extensible as possible. Extensibility isdesirable in order to maintain at least some non-broken fibers in thesidewalls around the perimeter of the protrusions. It may be desirablefor individual precursor webs, or at least one of the nonwovens within amulti-layer structure, to be capable of undergoing an elongation ofgreater than or equal to about one of the following amounts: 100% (thatis double its unstretched length), 110%, 120%, or 130% up to about 200%,or more, at or before reaching the peak tensile force. It is alsodesirable for the precursor nonwoven webs to be capable of undergoingplastic deformation to ensure that the structure of the deformations is“set” in place so that the nonwoven web will not tend to recover orreturn to its prior configuration.

Materials that are not extensible enough (e.g., inextensible PP) mayform broken fibers around much of the perimeter of the deformation, andcreate more of a “hanging chad” 90 (i.e., the cap 52 of the protrusions32 may be at least partially broken from and separated from the rest ofthe protrusion (as shown in FIG. 20). The area on the sides of theprotrusion where the fibers are broken is designated with referencenumber 92. Materials such as that shown in FIG. 20 will not be suitablefor a single layer structure, and, if used, will typically be part of acomposite multi-layer structure in which another layer has protrusions32 as described herein.

When the fibers of a nonwoven web are not very extensible, it may bedesirable for the nonwoven to be underbonded as opposed to optimallybonded. A thermally bonded nonwoven web's tensile properties can bemodified by changing the bonding temperature. A web can be optimally orideally bonded, underbonded or overbonded. Optimally or ideally bondedwebs are characterized by the highest peak tensile strength andelongation at tensile peak with a rapid decay in strength after tensilepeak. Under strain, bond sites fail and a small amount of fibers pullout of the bond site. Thus, in an optimally bonded nonwoven, the fibers38 will stretch and break around the bond sites 46 when the nonwoven webis strained beyond a certain point. Often there is a small reduction infiber diameter in the area surrounding the thermal point bond sites.Underbonded webs have a lower peak tensile strength and elongation attensile peak when compared to optimally bonded webs, with a slow decayin strength after tensile peak. Under strain, some fibers will pull outfrom the thermal point bond sites. Thus, in an underbonded nonwoven, atleast some of the fibers 38 can be separated easily from the bond sites46 to allow the fibers 38 to pull out of the bond sites and rearrangewhen the material is strained. Overbonded webs also have a lowered peaktensile strength and elongation at tensile peak when compared tooptimally bonded webs, with a rapid decay in strength after tensilepeak. The bond sites look like films and result in complete bond sitefailure under strain.

When the nonwoven web comprises two or more layers, the different layerscan have the same properties, or any suitable differences in propertiesrelative to each other. In one embodiment, the nonwoven web 30 cancomprise a two layer structure that is used in an absorbent article. Forconvenience, the precursor webs and the material into which they areformed are referred to herein by the same reference numbers. One of thelayers, a second layer 30B, can serve as the topsheet of the absorbentarticle, and the first layer 30A can be an underlying layer (orsub-layer) and serve as an acquisition layer. The acquisition layer 30Areceives liquids that pass through the topsheet and distributes them tounderlying absorbent layers. In such a case, the topsheet 30B may beless hydrophilic than sub-layer(s) 30A, which may lead to betterdewatering of the topsheet. In other embodiments, the topsheet can bemore hydrophilic than the sub-layer(s). In some cases, the pore size ofthe acquisition layer may be reduced, for example via using fibers withsmaller denier or via increasing the density of the acquisition layermaterial, to better dewater the pores of the topsheet.

The second nonwoven layer 30B that may serve as the topsheet can haveany suitable properties. Properties of interest for the second nonwovenlayer, when it serves as a topsheet, in addition to sufficientextensibility and plastic deformation may include uniformity andopacity. As used herein, “uniformity” refers to the macroscopicvariability in basis weight of a nonwoven web. As used, herein,“opacity” of nonwoven webs is a measure of the impenetrability of visuallight, and is used as visual determination of the relative fiber densityon a macroscopic scale. As used herein, “opacity” of the differentregions of a single nonwoven deformation is determined by taking aphotomicrograph at 20× magnification of the portion of the nonwovencontaining the deformation against a black background. Darker areasindicate relatively lower opacity (as well as lower basis weight andlower density) than white areas.

Several examples of nonwoven materials suitable for use as the secondnonwoven layer 30B include, but are not limited to: spunbondednonwovens; carded nonwovens; and other nonwovens with high extensibility(strain at peak tensile strength in the ranges set forth above) andsufficient plastic deformation to ensure the structure is set and doesnot have significant recovery. One suitable nonwoven material as atopsheet for a topsheet/acquisition layer composite structure may be anextensible spunbonded nonwoven comprising polypropylene andpolyethylene. The fibers can comprise a blend of polypropylene andpolyethylene, or they can be bi-component fibers, such as a sheath-corefiber with polyethylene on the sheath and polypropylene in the core ofthe fiber. Another suitable material is a bi-component fiber spunbondednonwoven comprising fibers with a polyethylene sheath and apolyethylene/polypropylene blend core.

The first nonwoven layer 30A that may, for example, serve as theacquisition layer can have any suitable properties. Properties ofinterest for the first nonwoven layer, in addition to sufficientextensibility and plastic deformation may include uniformity andopacity. If the first nonwoven layer 30A serves as an acquisition layer,its fluid handling properties must also be appropriate for this purpose.Such properties may include: permeability, porosity, capillary pressure,caliper, as well as mechanical properties such as sufficient resistanceto compression and resiliency to maintain void volume. Suitable nonwovenmaterials for the first nonwoven layer when it serves as an acquisitionlayer include, but are not limited to: spunbonded nonwovens; through-airbonded (“TAB”) carded nonwoven materials; spunlace nonwovens;hydroentangled nonwovens; and, resin bonded carded nonwoven materials.Of course, the composite structure may be inverted and incorporated intoan article in which the first layer 30A serves as the topsheet and thesecond layer 30B serves as an acquisition layer. In such cases, theproperties and exemplary methods of the first and second layersdescribed herein may be interchanged.

The layers of a two or more layered nonwoven web structure can becombined together in any suitable manner. In some cases, the layers canbe unbonded to each other and held together autogenously (that is, byvirtue of the formation of deformations therein). For example, bothprecursor webs 30A and 30B contribute fibers to deformations in a“nested” relationship that “locks” the two precursor webs together,forming a multi-layer web without the use or need for adhesives orthermal bonding between the layers. In other embodiments, the layers canbe joined together by other mechanisms. If desired an adhesive betweenthe layers, ultrasonic bonding, chemical bonding, resin or powderbonding, thermal bonding, or bonding at discrete sites using acombination of heat and pressure can be selectively utilized to bondcertain regions or all of the precursor webs. If adhesives are used,they can be applied in any suitable manner or pattern including, but notlimited to: slots, spirals, spray, and curtain coating. Adhesives can beapplied in any suitable amount or basis weight including, but notlimited to between about 0.5 and about 30 gsm, alternatively betweenabout 2 and about 5 gsm. In addition, the multiple layers may be bondedduring processing, for example, by carding one layer of nonwoven onto aspunbond nonwoven and thermal point bonding the combined layers. In somecases, certain types of bonding between layers may be excluded. Forexample, the layers of the present structure may be non-hydroentangledtogether.

When the precursor nonwoven web comprises two or more layers, it may bedesirable for at least one of the layers to be continuous, such as inthe form of a web that is unwound from a roll. In some embodiments, eachof the layers can be continuous. In alternative embodiments, such asshown in FIG. 24, one or more of the layers can be continuous, and oneor more of the layers can have a discrete length. The layers may alsohave different widths. For example, in making a combined topsheet andacquisition layer for an absorbent article, the nonwoven layer that willserve as the topsheet may be a continuous web, and the nonwoven layerthat will serve as the acquisition layer may be fed into themanufacturing line in the form of discrete length (for example,rectangular, or other shaped) pieces that are placed on top of thecontinuous web. Such an acquisition layer may, for example, have alesser width than the topsheet layer. The layers may be combinedtogether as described above.

Methods of Making the Nonwoven Materials

The nonwoven materials are made by a method comprising the steps of: a)providing at least one precursor nonwoven web; b) providing an apparatuscomprising a pair of forming members comprising a first forming memberand a second forming member; and c) placing the precursor nonwovenweb(s) between the forming members and mechanically deforming theprecursor nonwoven web(s) with the forming members. The forming membershave a machine direction (MD) orientation and a cross-machine direction(CD) orientation.

The first and second forming members can be plates, rolls, belts, or anyother suitable types of forming members. In some embodiments, it may bedesirable to modify the apparatus for incrementally stretching a webdescribed in U.S. Pat. No. 8,021,591, Curro, et al. entitled “Method andApparatus for Incrementally Stretching a Web” by providing theactivation members described therein with the forming elements of thetype described herein. In the embodiment of the apparatus 100 shown inFIG. 21, the first and second forming members 102 and 104 are in theform of non-deformable, meshing, counter-rotating rolls that form a nip106 therebetween. The precursor web(s) is/are fed into the nip 106between the rolls 102 and 104. Although the space between the rolls 102and 104 is described herein as a nip, as discussed in greater detailbelow, in some cases, it may be desirable to avoid compressing theprecursor web(s) to the extent possible.

First Forming Member.

The first forming member 102 has a surface comprising a plurality offirst forming elements which comprise discrete, spaced apart maleforming elements 112. The male forming elements are spaced apart in themachine direction and in the cross-machine direction. The term“discrete” does not include continuous or non-discrete forming elementssuch as the ridges and grooves on corrugated rolls (or “ring rolls”)which have ridges that may be spaced apart in one, but not both, of themachine direction and in the cross-machine direction.

As shown in FIG. 22, the male forming elements 112 have a base 116 thatis joined to (in this case is integral with) the first forming member102, a top 118 that is spaced away from the base, and sides 120 thatextend between the base and the top of the male forming elements. Themale elements 112 also have a plan view periphery, and a height H₁ (thelatter being measured from the base 116 to the top 118). The discreteelements on the male roll have a top 118 with a relatively large surfacearea (e.g., from about 1 mm to about 10 mm in width, and from about 1 mmto about 20 mm in length) for creating a wide deformation. The maleelements 112 may have any suitable configuration. In one embodiment, themale elements 112 have a flat top 118, vertical sidewalls 120, aradiused edge forming the transition 122 between the flat top 118 andvertical sidewalls 120 (by vertical side walls, it is meant that theside walls 120 have zero degree side wall angles relative to theperpendicular from the base of the side wall). The top 118 of the maleelements 112 may have any suitable plan view configuration, includingbut not limited to: a rounded diamond configuration as shown in FIGS. 21and 22, and an American football-like shape, triangle, clover, teardrop,oval, elliptical.

Numerous other embodiments of the male forming elements 112 arepossible. In other embodiments, the top 118 of the male forming elements112 can be rounded. In other embodiments, the side walls 120 can betapered inwardly toward the center of the male forming elements 112 sothat the side walls form an angle greater than zero. In otherembodiments, the top 118 of the male elements 112 can be of differentshapes from those shown in the drawings. In other embodiments, the maleforming elements 112 can be disposed in other orientations on the firstforming member 102 rather than having their length oriented in themachine direction (including CD-orientations, and orientations betweenthe MD and CD).

Second Forming Member.

As shown in FIG. 21, the second forming member 104 has a surface 124having a plurality of cavities or recesses 114 therein. The recesses 114are aligned and configured to receive the male forming elements 112therein. Thus, the male forming elements 112 mate with the recesses 114so that a single male forming element 112 fits within the periphery of asingle recess 114, and at least partially within the recess 114 in thez-direction. The recesses 114 have a plan view periphery 126 that islarger than the plan view periphery of the male elements 112. As aresult, the recess 114 on the female roll completely encompasses thediscrete male element 112 when the rolls 102 and 104 are intermeshed.The recesses 114 have a depth D₁ shown in FIG. 23. In some cases, thedepth D₁ of the recesses may be greater than the height H₁ of the maleforming elements 112.

The recesses 114 may have a similar plan view configuration as the maleelements 112, side walls 128, and an edge 130 around the bottom 132 ofthe recesses where the side walls 128 meet the bottom 132 of therecesses. The side walls 128 of the recesses 114 may be vertical. Theedge 130 of the recesses may be sharp or rounded.

As discussed above, the recesses 114 may be deeper than the height H₁ ofthe male elements 112 so the nonwoven material is not nipped (orsqueezed) between the male and female rolls 102 and 104 to the extentpossible. However, it is understood that passing the precursor web(s)between two rolls with a relatively small space therebetween will likelyapply some shear and compressive forces to the web(s). The presentmethod, however, differs from some embossing processes in which the topof the male elements compress the material to be embossed against thebottom of the female elements, thereby increasing the density of theregion in which the material is compressed.

The depth of engagement (DOE) is a measure of the level of intermeshingof the forming members. As shown in FIG. 23, the DOE is measured fromthe top 118 of the male elements 112 to the outermost surface 124 of thefemale forming member 114 (e.g., the roll with recesses). The DOE shouldbe sufficiently high, when combined with extensible nonwoven materials,to create protrusions 32 having a distal portion or cap 52 with amaximum width that is greater than the width of the base opening 44. TheDOE may, for example, range from at least about 1.5 mm, or less, toabout 5 mm, or more. In certain embodiments, the DOE may be betweenabout 2.5 mm to about 5 mm, alternatively between about 3 mm and about 4mm. The formation of protrusions 32 having a distal portion with amaximum width that is greater than the width of the base opening 44 isbelieved to differ from most embossing processes in which theembossments typically take the configuration of the embossing elements,which have a base opening that is wider than the remainder of theembossments. As shown in FIG. 23, there is a clearance, C, between thesides 120 of the male elements 112 and the sides (or side walls) 128 ofthe recesses 114. The clearance, C, between the male and female roll maybe the same, or it may vary slightly around the perimeter of the maleelement. Clearances can range from about 0.005 inches (0.13 mm) to about0.05 inches (1.3 mm). The clearances and the DOE's are related such thatlarger clearances can permit higher DOE's to be used.

The precursor nonwoven web is placed between the forming members 102 and104. The precursor nonwoven web can be placed between the formingmembers with either side of the precursor web (first surface 34 orsecond surface 36) facing the first forming member, male forming member102. For convenience of description, the second surface 36 of theprecursor nonwoven web will be described herein as being placed incontact with the first forming member 102. (Of course, in otherembodiments, the second surface 36 of the precursor nonwoven web can beplaced in contact with the second forming member 104.) The precursormaterial is mechanically deformed with the forming members 102 and 104when a force is applied on the nonwoven web with the forming members 102and 104. The force can be applied in any suitable manner. If the formingmembers 102 and 104 are in the form of plates, the force will be appliedwhen the plates are brought together. If the forming members 102 and 104are in the form of counter-rotating rolls (or belts, or any combinationof rolls and belts), the force will be applied when the precursornonwoven web passes through the nip between the counter-rotatingelements. The force applied by the forming members impacts the precursorweb and mechanically deforms the precursor nonwoven web.

When deforming multiple webs that are laminated together with anadhesive, it may be desirable to chill the forming members in order toavoid glue sticking to and fouling the forming members. The formingmembers can be chilled using processes know in the art. One such processcould be an industrial chiller that utilizes a coolant, such aspropylene glycol. In some cases, it may be desirable to operate theprocess in a humid environment such that a layer of condensate forms onthe forming members.

The precursor nonwoven web forms nonwoven web comprising a generallyplanar first region and a plurality of discrete integral second regionsthat comprise deformations comprising protrusions extending outward fromthe first surface 34 of the nonwoven web and openings in the secondsurface of the nonwoven web. (Of course, if the second surface 36 of theprecursor nonwoven web is placed in contact with the second formingmember 104, the protrusions will extend outward from the second surfaceof the nonwoven web and the openings will be formed in the first surfaceof the nonwoven web.) Without wishing to be bound by any particulartheory, it is believed that the extensibility of the precursor web (orat least one of the layers of the same) when pushed by the male formingelements 112 into the recesses 114 with depth of engagement DOE beingless than the depth D₁ of the recesses, stretches a portion of thenonwoven web to form a deformation comprising a protrusion with theenlarged cap and wide base opening described above. (This can beanalogized to sticking one's finger into an uninflated balloon tostretch and permanently deform the material of the balloon.)

In cases in which the precursor nonwoven material 30 comprises more thanone layer, and one of the layers is in the form of discrete pieces ofnonwoven material, as shown in FIG. 24, it may be desirable for thedeformations to be formed so that the base openings are in thecontinuous layer (such as 30B) and the protrusions 32 extend toward thediscrete layer (such as 30A). Of course, in other embodiments, thedeformations in such a structure can be in the opposite orientation. Thedeformations can be distributed in any suitable manner over the surfacesof such continuous and discrete layers. For example, the deformationscan: be distributed over the full length and/or width of the continuouslayer; be distributed in an area narrower than the width of thecontinuous layer; or be limited to the area of the discrete layer.

The method of making the nonwoven materials described herein may exclude(or be distinguishable from) the following processes: hydroforming(hydroentangling); hydromolding; use of air jets; rigid-to-resilient(e.g., steel/rubber) embossing; and the use of a patterned surfaceagainst a flat anvil surface. The method may also exclude (or bedistinguishable from) The Procter & Gamble Company's processes formaking Structural Elastic-Like Films (“SELF” processes). The formingmembers used herein differ from the forming members used in SELFingprocesses to form corrugated structures (and tufted structures) in thatthe SELF teeth typically have a comparatively small diameter tip, andthe ridges of the mating ring roll only border the SELF teeth on thesides, and not the front and back of the teeth.

Absorbent Articles

Three-dimensional nonwoven materials and the method of their manufactureof the present disclosure have been discussed above. The use of thosethree-dimensional nonwoven materials is now explained in further detailin the context of example absorbent articles.

General Description of an Absorbent Article

An example absorbent article in the form of a diaper 220 is representedin FIGS. 28-30. FIG. 28 is a plan view of the example diaper 220, in aflat, laid-out state, with portions of the structure being cut-away tomore clearly show the construction of the diaper 220. The wearer-facingsurface of the diaper 220 of FIG. 28 is facing the viewer. This diaper220 is shown for illustration purpose only as the three-dimensionalnonwoven materials of the present disclosure may be used as one or morecomponents of an absorbent article, such as the topsheet, theacquisition layer, the topsheet and the acquisition layer individually,or the topsheet and the acquisition layer as a laminate. In any eventthe three-dimensional nonwoven materials of the present disclosure maybe liquid permeable.

The absorbent article 220 may comprise a liquid permeable material ortopsheet 224, a liquid impermeable material or backsheet 225, anabsorbent core 228 positioned at least partially intermediate thetopsheet 224 and the backsheet 225, and barrier leg cuffs 234. Theabsorbent article may also comprise an ADS 250, which in the examplerepresented comprises a distribution layer 254 and an acquisition layer252, which will be further discussed below. The absorbent article 220may also comprise elasticized gasketing cuffs 232 comprising elastics233 joined to a chassis of the absorbent article, typically via thetopsheet and/or backsheet, and substantially planar with the chassis ofthe diaper.

FIGS. 28 and 31 also show typical taped diaper components such as afastening system comprising tabs 242 attached towards the rear edge ofthe article and cooperating with a landing zone 244 on the front of theabsorbent article. The absorbent article may also comprise other typicalelements, which are not represented, such as a rear elastic waistfeature, a front elastic waist feature, transverse barrier cuff(s),and/or a lotion application, for example.

The absorbent article 220 comprises a front waist edge 210, a rear waistedge 212 longitudinally opposing the front waist edge 210, a first sideedge 203, and a second side edge 204 laterally opposing the first sideedge 203. The front waist edge 210 is the edge of the article which isintended to be placed towards the front of the user when worn, and therear waist edge 212 is the opposite edge. The absorbent article 220 mayhave a longitudinal axis 280 extending from the lateral midpoint of thefront waist edge 210 to a lateral midpoint of the rear waist edge 212 ofthe article and dividing the article in two substantially symmetricalhalves relative to the longitudinal axis 280, with the article placedflat, laid-out and viewed from above as in FIG. 28. The absorbentarticle 220 may also have a lateral axis 290 extending from thelongitudinal midpoint of the first side edge 203 to the longitudinalmidpoint of the second side edge 204. The length, L, of the article maybe measured along the longitudinal axis 280 from the front waist edge210 to the rear waist edge 212. The width, W, of the absorbent articlemay be measured along the lateral axis 290 from the first side edge 203to the second side edge 204. The absorbent article may comprise a crotchpoint C defined herein as the point placed on the longitudinal axis at adistance of two fifth (⅖) of L starting from the front edge 210 of thearticle 220. The article may comprise a front waist region 205, a rearwaist region 206, and a crotch region 207. The front waist region 205,the rear waist region 206, and the crotch region 207 may each define ⅓of the longitudinal length, L, of the absorbent article. The topsheet224, the backsheet 225, the absorbent core 228, and the other articlecomponents may be assembled in a variety of configurations, inparticular by gluing or heat embossing, for example.

The absorbent core 228 may comprise an absorbent material comprising atleast 80% by weight, at least 85% by weight, at least 90% by weight, atleast 95% by weight, or at least 99% by weight of superabsorbentpolymers, and a core wrap enclosing the superabsorbent polymers. Thecore wrap may typically comprise two materials, substrates, or nonwovenmaterials 216 and 216′ for the top side and the bottom side of the core.These types of cores are known as airfelt-free cores. The core maycomprise one or more channels, represented in FIG. 28 as the fourchannels 226, 226′ and 227, 227′. The channels 226, 226′, 227, and 227′are optional features. Instead, the core may not have any channels ormay have any number of channels.

These and other components of the example absorbent articles will now bediscussed in more details.

Topsheet

In the present disclosure, the topsheet (the portion of the absorbentarticle that contacts the wearer's skin and receives the fluids) may beformed of a portion of, or all of, one or more of the three-dimensionalnonwoven materials described herein and/or have one or more of thenonwoven materials positioned thereon and/or joined thereto, so that thenonwoven material(s) contact(s) the wearer's skin. Other portions of thetopsheet (other than the three-dimensional nonwoven materials) may alsocontact the wearer's skin. The three-dimensional nonwoven materials maybe positioned as a strip or a patch on top of the typical topsheet 224.Alternatively, the three-dimensional nonwoven material may only form acentral CD area of the topsheet. The central CD area may extend the fullMD length of the topsheet or less than the full MD length of thetopsheet.

The topsheet 224 may be joined to the backsheet 225, the absorbent core228 and/or any other layers as is known to those of skill in the art.Usually, the topsheet 224 and the backsheet 225 are joined directly toeach other in some locations (e.g., on or close to the periphery of theabsorbent article) and are indirectly joined together in other locationsby directly joining them to one or more other elements of the article220.

The topsheet 224 may be compliant, soft-feeling, and non-irritating tothe wearer's skin. Further, a portion of, or all of, the topsheet 224may be liquid permeable, permitting liquids to readily penetrate throughits thickness. Any portion of the topsheet 224 may be coated with alotion and/or a skin care composition as is generally disclosed in theart. The topsheet 224 may also comprise or be treated with antibacterialagents.

Backsheet

The backsheet 225 is generally that portion of the absorbent article 220positioned adjacent the garment-facing surface of the absorbent core 228and which prevents, or at least inhibits, the fluids and bodily exudatesabsorbed and contained therein from soiling articles such as bedsheetsand undergarments. The backsheet 225 is typically impermeable, or atleast substantially impermeable, to fluids (e.g., urine). The backsheetmay, for example, be or comprise a thin plastic film such as athermoplastic film having a thickness of about 0.012 mm to about 0.051mm. Other suitable backsheet materials may include breathable materialswhich permit vapors to escape from the absorbent article 220, whilestill preventing, or at least inhibiting, fluids from passing throughthe backsheet 225.

The backsheet 225 may be joined to the topsheet 224, the absorbent core228, and/or any other element of the absorbent article 220 by anyattachment methods known to those of skill in the art.

An outer cover 223 of the absorbent article 220 may cover at least aportion of, or all of, the backsheet 225 to form a soft garment-facingsurface of the absorbent article. The outer cover 223 may be formed ofthe high loft, three-dimensional nonwoven materials described herein.Alternatively, the outer cover 223 may comprise one or more known outercover materials. If the outer cover 223 comprises one of thethree-dimensional nonwoven materials of the present disclosure, thethree-dimensional nonwoven material of the outer cover 223 may or maynot match (e.g., same material, same pattern) a three-dimensionalnonwoven material used as the topsheet or the topsheet and theacquisition layer of the absorbent article. In other instances, theouter cover may have a printed or otherwise applied pattern that matchesor visually resembles the pattern of the three-dimensional nonwovenmaterials used as the topsheet or the topsheet and the acquisition layerlaminate of the absorbent article. The outer cover 223 is illustrated indash in FIG. 29, as an example. The outer cover 223 may be joined to atleast a portion of the backsheet 225 through mechanical bonding,adhesive bonding, or other suitable methods of attachment.

Absorbent Core

The absorbent core is the component of the absorbent article that hasthe most absorbent capacity and that comprises an absorbent material anda core wrap or core bag enclosing the absorbent material. The absorbentcore does not include the acquisition and/or distribution system or anyother components of the absorbent article which are not either integralpart of the core wrap or core bag or placed within the core wrap or corebag. The absorbent core may comprise, consist essentially of, or consistof, a core wrap, an absorbent material (e.g., superabsorbent polymersand little or no cellulose fibers) as discussed, and glue. In otherinstances, the absorbent material may comprise a mixture ofsuperabsorbent polymers and air-felt or cellulose fibers. This mixtureof superabsorbent polymers and air-felt or cellulose fibers may bepositioned within the core bag. The core bag may form a C-wrap aroundthe mixture or may be otherwise formed. Glue may also be present withinthe core bag to at least partially hold the mixture in place duringmanufacture and wear.

The absorbent core 228 may comprise an absorbent material with a highamount of superabsorbent polymers (herein abbreviated as “SAP”) enclosedwithin the core wrap. The SAP content may represent 70%-100% or at least70%, 75%, 80%, 85%, 90%, 95%, 99%, or 100%, by weight of the absorbentmaterial, contained in the core wrap. The core wrap is not considered asabsorbent material for the purpose of assessing the percentage of SAP inthe absorbent core.

By “absorbent material” it is meant a material which has some absorbencyproperty or liquid retaining properties, such as SAP, cellulosic fibersas well as synthetic fibers. Typically, glues used in making absorbentcores have no or little absorbency properties and are not considered asabsorbent material. The SAP content may be higher than 80%, for exampleat least 85%, at least 90%, at least 95%, at least 99%, and even up toand including 100% of the weight of the absorbent material containedwithin the core wrap. This airfelt-free core is relatively thin comparedto a conventional core typically comprising between 40-60% SAP by weightand a high content of cellulose fibers. The absorbent material may inparticular comprises less than 15% weight percent or less than 10%weight percent of natural, cellulosic, or synthetic fibers, less than 5%weight percent, less than 3% weight percent, less than 2% weightpercent, less than 1% weight percent, or may even be substantially freeof natural, cellulosic, and/or synthetic fibers.

As referenced above, the airfelt-free cores with very little or nonatural, cellulosic and/or synthetic fibers are quite thin compared toconventional cores, thereby making the overall absorbent article thinnerthan absorbent articles with cores comprising mixed SAP and cellulosicfibers (e.g., 40-60% cellulose fibers). This core thinness can lead toconsumer perceptions of reduced absorbency and performance, althoughtechnically this is not the case. Presently, these thin cores havetypically been used with substantially planer or apertured topsheets.Furthermore, absorbent articles having these thin airfelt-free coreshave reduced capillary void space since there is little or no natural,cellulosic, or synthetic fibers in the cores. Thus, there may sometimesnot be enough capillary void space in the absorbent article to fullyaccept multiple insults of bodily exudates or a single large insult.

To solve such problems, the present disclosure provides absorbentarticles with these thin airfelt-free cores in combination with one ofthe high-loft, three-dimensional nonwoven materials described herein asa topsheet, an acquisition layer, or as a topsheet and acquisition layerlaminate. In such an instance, consumer perception of absorbency andperformance, through the increased thickness of the absorbent articleowing to the additional thickness provided by the high-loft,three-dimensional nonwoven material, is increased. Furthermore, thethree-dimensional nonwoven materials, when used with these thinairfelt-free cores and as the topsheet, and the acquisition layer, orthe topsheet and acquisition layer laminate, add capillary void spaceback into the absorbent articles, while still allowing for minimal stackheights, thereby passing cost savings onto consumers and manufactures.As such, the absorbent articles of the present disclosure may easilyabsorb multiple bodily exudate insults or single large insults owing tothis increased capillary void space. Additionally, absorbent articlesthat comprise the nonwoven materials as the topsheet, the acquisitionlayer, or the topsheet and acquisition layer laminate provide consumerswith an aesthetically pleasing topsheet relative to a planer topsheet oran apertured topsheet with an increased thickness and thus the consumerperceptions of absorbency and performance.

The example absorbent core 228 of the absorbent article 220 of FIGS.31-32 is shown in isolation in FIGS. 33-35. The absorbent core 228 maycomprises a front side 480, a rear side 482, and two longitudinal sides484, 486 joining the front side 480 and the rear side 482. The absorbentcore 228 may also comprise a generally planar top side and a generallyplanar bottom side. The front side 480 of the core is the side of thecore intended to be placed towards the front waist edge 210 of theabsorbent article. The core 228 may have a longitudinal axis 280′corresponding substantially to the longitudinal axis 280 of theabsorbent article 220, as seen from the top in a planar view as in FIG.28. The absorbent material may be distributed in higher amount towardsthe front side 480 than towards the rear side 482 as more absorbency maybe required at the front in particular absorbent articles. The front andrear sides 480 and 482 of the core may be shorter than the longitudinalsides 484 and 486 of the core. The core wrap may be formed by twononwoven materials, substrates, laminates, or other materials, 216, 216′which may be at least partially sealed along the sides 484, 486 of theabsorbent core 228. The core wrap may be at least partially sealed alongits front side 480, rear side 482, and two longitudinal sides 484, 486so that substantially no absorbent material leaks out of the absorbentcore wrap. The first material, substrate, or nonwoven 216 may at leastpartially surround the second material, substrate, or nonwoven 216′ toform the core wrap, as illustrated in FIG. 34. The first material 216may surround a portion of the second material 216′ proximate to thefirst and second side edges 484 and 486.

The absorbent core may comprise adhesive, for example, to helpimmobilizing the SAP within the core wrap and/or to ensure integrity ofthe core wrap, in particular when the core wrap is made of two or moresubstrates. The adhesive may be a hot melt adhesive, supplied, by H. B.Fuller, for example. The core wrap may extend to a larger area thanstrictly needed for containing the absorbent material within.

The absorbent material may be a continuous layer present within the corewrap. Alternatively, the absorbent material may be comprised ofindividual pockets or stripes of absorbent material enclosed within thecore wrap. In the first case, the absorbent material may be, forexample, obtained by the application of a single continuous layer ofabsorbent material. The continuous layer of absorbent material, inparticular of SAP, may also be obtained by combining two absorbentlayers having discontinuous absorbent material application patterns,wherein the resulting layer is substantially continuously distributedacross the absorbent particulate polymer material area, as disclosed inU.S. Pat. Appl. Pub. No. 2008/0312622A1 (Hundorf), for example. Theabsorbent core 228 may comprise a first absorbent layer and a secondabsorbent layer. The first absorbent layer may comprise the firstmaterial 216 and a first layer 261 of absorbent material, which may be100% or less of SAP. The second absorbent layer may comprise the secondmaterial 216′ and a second layer 262 of absorbent material, which mayalso be 100% or less of SAP. The absorbent core 228 may also comprise afibrous thermoplastic adhesive material 251 at least partially bondingeach layer of absorbent material 261, 262 to its respective material 216or 216′. This is illustrated in FIGS. 34-35, as an example, where thefirst and second SAP layers have been applied as transversal stripes or“land areas” having the same width as the desired absorbent materialdeposition area on their respective substrate before being combined. Thestripes may comprise different amounts of absorbent material (SAP) toprovide a profiled basis weight along the longitudinal axis of the core280. The first material 216 and the second material 216′ may form thecore wrap.

The fibrous thermoplastic adhesive material 251 may be at leastpartially in contact with the absorbent material 261, 262 in the landareas and at least partially in contact with the materials 216 and 216′in the junction areas. This imparts an essentially three-dimensionalstructure to the fibrous layer of thermoplastic adhesive material 251,which in itself is essentially a two-dimensional structure of relativelysmall thickness, as compared to the dimension in length and widthdirections. Thereby, the fibrous thermoplastic adhesive material mayprovide cavities to cover the absorbent material in the land areas, andthereby immobilizes this absorbent material, which may be 100% or lessof SAP.

The thermoplastic adhesive used for the fibrous layer may haveelastomeric properties, such that the web formed by the fibers on theSAP layer is able to be stretched as the SAP swell.

Superabsorbent Polymer (SAP)

The SAP useful with the present disclosure may include a variety ofwater-insoluble, but water-swellable polymers capable of absorbing largequantities of fluids.

The superabsorbent polymer may be in particulate form so as to beflowable in the dry state. Particulate absorbent polymer materials maybe made of poly(meth)acrylic acid polymers. However, starch-basedparticulate absorbent polymer material may also be used, as well aspolyacrylamide copolymer, ethylene maleic anhydride copolymer,cross-linked carboxymethylcellulose, polyvinyl alcohol copolymers,cross-linked polyethylene oxide, and starch grafted copolymer ofpolyacrylonitrile.

The SAP may be of numerous shapes. The term “particles” refers togranules, fibers, flakes, spheres, powders, platelets and other shapesand forms known to persons skilled in the art of superabsorbent polymerparticles. The SAP particles may be in the shape of fibers, i.e.,elongated, acicular superabsorbent polymer particles. The fibers mayalso be in the form of a long filament that may be woven. SAP may bespherical-like particles. The absorbent core may comprise one or moretypes of SAP.

For most absorbent articles, liquid discharges from a wearer occurpredominately in the front half of the absorbent article, in particularfor a diaper. The front half of the article (as defined by the regionbetween the front edge and a transversal line placed at a distance ofhalf L from the front waist edge 210 or rear waist edge 212 maytherefore may comprise most of the absorbent capacity of the core. Thus,at least 60% of the SAP, or at least 65%, 70%, 75%, 80%, or 85% of theSAP may be present in the front half of the absorbent article, while theremaining SAP may be disposed in the rear half of the absorbent article.Alternatively, the SAP distribution may be uniform through the core ormay have other suitable distributions.

The total amount of SAP present in the absorbent core may also varyaccording to expected user. Diapers for newborns may require less SAPthan infant, child, or adult incontinence diapers. The amount of SAP inthe core may be about 5 to 60 g or from 5 to 50 g. The average SAP basisweight within the (or “at least one”, if several are present) depositionarea 8 of the SAP may be at least 50, 100, 200, 300, 400, 500 or moreg/m². The areas of the channels (e.g., 226, 226′, 227, 227′) present inthe absorbent material deposition area 8 are deduced from the absorbentmaterial deposition area to calculate this average basis weight.

Core Wrap

The core wrap may be made of a single substrate, material, or nonwovenfolded around the absorbent material, or may comprise two (or more)substrates, materials, or nonwovens which are attached to another.Typical attachments are the so-called C-wrap and/or sandwich wrap. In aC-wrap, as illustrated, for example, in FIGS. 29 and 34, thelongitudinal and/or transversal edges of one of the substrates arefolded over the other substrate to form flaps. These flaps are thenbonded to the external surface of the other substrate, typically bygluing.

The core wrap may be formed by any materials suitable for receiving andcontaining the absorbent material. Typical substrate materials used inthe production of conventional cores may be used, in particular paper,tissues, films, wovens or nonwovens, or laminates or composites of anyof these.

The substrates may also be air-permeable (in addition to being liquid orfluid permeable). Films useful herein may therefore comprisemicro-pores.

The core wrap may be at least partially sealed along all the sides ofthe absorbent core so that substantially no absorbent material leaks outof the core. By “substantially no absorbent material” it is meant thatless than 5%, less than 2%, less than 1%, or about 0% by weight ofabsorbent material escape the core wrap. The term “seal” is to beunderstood in a broad sense. The seal does not need to be continuousalong the whole periphery of the core wrap but may be discontinuousalong part or the whole of it, such as formed by a series of seal pointsspaced on a line. A seal may be formed by gluing and/or thermal bonding.

If the core wrap is formed by two substrates 216, 216′, four seals maybe used to enclose the absorbent material 260 within the core wrap. Forexample, a first substrate 216 may be placed on one side of the core(the top side as represented in FIGS. 33-35) and extend around thecore's longitudinal edges to at least partially wrap the opposed bottomside of the core. The second substrate 216′ may be present between thewrapped flaps of the first substrate 216 and the absorbent material 260.The flaps of the first substrate 216 may be glued to the secondsubstrate 216′ to provide a strong seal. This so called C-wrapconstruction may provide benefits such as improved resistance tobursting in a wet loaded state compared to a sandwich seal. The frontside and rear side of the core wrap may then also be sealed by gluingthe first substrate and second substrate to another to provide completeencapsulation of the absorbent material across the whole of theperiphery of the core. For the front side and rear side of the core, thefirst and second substrates may extend and may be joined together in asubstantially planar direction, forming for these edges a so-calledsandwich construction. In the so-called sandwich construction, the firstand second substrates may also extend outwardly on all sides of the coreand be sealed flat, or substantially flat, along the whole or parts ofthe periphery of the core typically by gluing and/or heat/pressurebonding. In an example, neither the first nor the second substrates needto be shaped, so that they may be rectangularly cut for ease ofproduction but other shapes are also within the scope of the presentdisclosure.

The core wrap may also be formed by a single substrate which may encloseas in a parcel wrap the absorbent material and be sealed along the frontside and rear side of the core and one longitudinal seal.

SAP Deposition Area

The absorbent material deposition area 208 may be defined by theperiphery of the layer formed by the absorbent material 260 within thecore wrap, as seen from the top side of the absorbent core. Theabsorbent material deposition area 208 may have various shapes, inparticular, a so-called “dog bone” or “hour-glass” shape, which shows atapering along its width towards the middle or “crotch” region of thecore. In this way, the absorbent material deposition area 8 may have arelatively narrow width in an area of the core intended to be placed inthe crotch region of the absorbent article, as illustrated in FIG. 28.This may provide better wearing comfort. The absorbent materialdeposition area 8 may also be generally rectangular, for example asshown in FIGS. 31-33, but other deposition areas, such as a rectangular,“T,” “Y,” “sand-hour,” or “dog-bone” shapes are also within the scope ofthe present disclosure. The absorbent material may be deposited usingany suitable techniques, which may allow relatively precise depositionof SAP at relatively high speed.

Channels

The absorbent material deposition area 208 may comprise at least onechannel 226, which is at least partially oriented in the longitudinaldirection of the article 280 (i.e., has a longitudinal vectorcomponent). Other channels may be at least partially oriented in thelateral direction (i.e., has a lateral vector component) or in any otherdirection. In the following, the plural form “channels” will be used tomean “at least one channel”. The channels may have a length L′ projectedon the longitudinal axis 280 of the article that is at least 10% of thelength L of the article. The channels may be formed in various ways. Forexample, the channels may be formed by zones within the absorbentmaterial deposition area 208 which may be substantially free of, or freeof, absorbent material, in particular SAP. In addition or alternatively,the channel(s) may also be formed by continuously or discontinuouslybonding the top side of the core wrap to the bottom side of the corewrap through the absorbent material deposition area 208. The channelsmay be continuous, but it is also envisioned that the channels may beintermittent. The acquisition-distribution system or layer 250, oranother layer of the article, may also comprise channels, which may ornot correspond to the channels of the absorbent core.

In some instances, the channels may be present at least at the samelongitudinal level as the crotch point C or the lateral axis 260 in theabsorbent article, as represented in FIG. 28 with the two longitudinallyextending channels 226, 226′. The channels may also extend from thecrotch region 207 or may be present in the front waist region 205 and/orin the rear waist region 206 of the article.

The absorbent core 228 may also comprise more than two channels, forexample, at least 3, at least 4, at least 5, or at least 6 or more.Shorter channels may also be present, for example in the rear waistregion 206 or the front waist region 205 of the core as represented bythe pair of channels 227, 227′ in FIG. 28 towards the front of thearticle. The channels may comprise one or more pairs of channelssymmetrically arranged, or otherwise arranged relative to thelongitudinal axis 280.

The channels may be particularly useful in the absorbent core when theabsorbent material deposition area is rectangular, as the channels mayimprove the flexibility of the core to an extent that there is lessadvantage in using a non-rectangular (shaped) core. Of course channelsmay also be present in a layer of SAP having a shaped deposition area.

The channels may be completely oriented longitudinally and parallel tothe longitudinal axis or completely oriented transversely and parallelto the lateral axis, but also may have at least portions that arecurved.

In order to reduce the risk of fluid leakages, the longitudinal mainchannels may not extend up to any of the edges of the absorbent materialdeposition area 208, and may therefore be fully encompassed within theabsorbent material deposition area 208 of the core. The smallestdistance between a channel and the closest edge of the absorbentmaterial deposition area 208 may be at least 5 mm.

The channels may have a width We along at least part of their lengthwhich is at least 2 mm, at least 3 mm, at least 4 mm, up to for example20 mm, 16 mm, or 12 mm, for example. The width of the channel(s) may beconstant through substantially the whole length of the channel or mayvary along its length. When the channels are formed by absorbentmaterial-free zone within the absorbent material deposition area 208,the width of the channels is considered to be the width of the materialfree zone, disregarding the possible presence of the core wrap withinthe channels. If the channels are not formed by absorbent material freezones, for example mainly though bonding of the core wrap through theabsorbent material zone, the width of the channels is the width of thisbonding.

At least some or all of the channels may be permanent channels, meaningtheir integrity is at least partially maintained both in the dry stateand in the wet state. Permanent channels may be obtained by provision ofone or more adhesive materials, for example, the fibrous layer ofadhesive material or construction glue that helps adhere a substratewith an absorbent material within the walls of the channel. Permanentchannels may also be formed by bonding the upper side and lower side ofthe core wrap (e.g., the first substrate 216 and the second substrate216′) and/or the topsheet 224 to the backsheet 225 together through thechannels. Typically, an adhesive may be used to bond both sides of thecore wrap or the topsheet and the backsheet through the channels, but itis possible to bond via other known processes, such as pressure bonding,ultrasonic bonding, heat bonding, or combination thereof. The core wrapor the topsheet 224 and the backsheet 225 may be continuously bonded orintermittently bonded along the channels. The channels mayadvantageously remain or become visible at least through the topsheetand/or backsheet when the absorbent article is fully loaded with afluid. This may be obtained by making the channels substantially free ofSAP, so they will not swell, and sufficiently large so that they willnot close when wet. Furthermore, bonding the core wrap to itself or thetopsheet to the backsheet through the channels may be advantageous.

Barrier Leg Cuffs

The absorbent article may comprise a pair of barrier leg cuffs 34. Eachbarrier leg cuff may be formed by a piece of material which is bonded tothe absorbent article so it may extend upwards from a wearer-facingsurface of the absorbent article and provide improved containment offluids and other body exudates approximately at the junction of thetorso and legs of the wearer. The barrier leg cuffs are delimited by aproximal edge 64 joined directly or indirectly to the topsheet 224and/or the backsheet 225 and a free terminal edge 266, which is intendedto contact and form a seal with the wearer's skin. The barrier leg cuffs234 extend at least partially between the front waist edge 210 and therear waist edge 212 of the absorbent article on opposite sides of thelongitudinal axis 280 and are at least present at the level of thecrotch point (C) or crotch region. The barrier leg cuffs may be joinedat the proximal edge 264 with the chassis of the article by a bond 265which may be made by gluing, fusion bonding, or a combination of othersuitable bonding processes. The bond 265 at the proximal edge 264 may becontinuous or intermittent. The bond 265 closest to the raised sectionof the leg cuffs delimits the proximal edge 264 of the standing upsection of the leg cuffs.

The barrier leg cuffs may be integral with the topsheet 224 or thebacksheet 225 or may be a separate material joined to the article'schassis. Each barrier leg cuff 234 may comprise one, two or more elasticstrings 235 close to the free terminal edge 266 to provide a betterseal.

In addition to the barrier leg cuffs 234, the article may comprisegasketing cuffs 232, which are joined to the chassis of the absorbentarticle, in particular to the topsheet 224 and/or the backsheet 225 andare placed externally relative to the barrier leg cuffs. The gasketingcuffs 232 may provide a better seal around the thighs of the wearer.Each gasketing leg cuff may comprise one or more elastic strings orelastic elements 233 in the chassis of the absorbent article between thetopsheet 224 and backsheet 225 in the area of the leg openings. All, ora portion of, the barrier leg cuffs and/or gasketing cuffs may betreated with a lotion or another skin care composition.

Acquisition-Distribution System

The absorbent articles of the present disclosure may comprise anacquisition-distribution layer or system 250 (“ADS”). One function ofthe ADS is to quickly acquire one or more of the fluids and distributethem to the absorbent core in an efficient manner. The ADS may compriseone, two or more layers, which may form a unitary layer or may remain asdiscrete layers which may be attached to each other. In an example, theADS may comprise two layers: a distribution layer 254 and an acquisitionlayer 252 disposed between the absorbent core and the topsheet, but thepresent disclosure is not so limited.

In one example, the high loft, three-dimensional nonwoven materials ofthe present disclosure may comprise the topsheet and the acquisitionlayer as a laminate. A distribution layer may also be provided on thegarment-facing side of the topsheet/acquisition layer laminate.

In another example, the high loft, three dimensional nonwoven materialsof the present disclosure may comprise an acquisition layer of anabsorbent article and a topsheet of the absorbent article may begenerally planar. The topsheet may have an opacity such that theacquisition layer, such as a colored acquisition layer or an acquisitionlayer with indicia, is visible through the topsheet from thewearer-facing side of the absorbent article.

Carrier Layer

In an instance where the high loft, three-dimensional nonwoven materialsof the present disclosure encompass a topsheet and acquisition layerlaminate, the distribution layer may need to be supported by a carrierlayer (not illustrated) that may comprise one or more nonwoven materialsor other materials. The distribution layer may be applied to orpositioned on the carrier layer. As such, the carrier layer may bepositioned intermediate the acquisition layer and the distribution layerand be in a facing relationship with the acquisition layer and thedistribution layer.

Distribution Layer

The distribution layer of the ADS may comprise at least 50% by weight ofcross-linked cellulose fibers. The cross-linked cellulosic fibers may becrimped, twisted, or curled, or a combination thereof including crimped,twisted, and curled. This type of material is disclosed in U.S. Pat.Publ. No. 2008/0312622 A1 (Hundorf). The cross-linked cellulosic fibersprovide higher resilience and therefore higher resistance to the firstabsorbent layer against the compression in the product packaging or inuse conditions, e.g., under wearer weight. This may provide the corewith a higher void volume, permeability, and liquid absorption, andhence reduced leakage and improved dryness.

The distribution layer comprising the cross-linked cellulose fibers ofthe present disclosure may comprise other fibers, but this layer mayadvantageously comprise at least 50%, or 60%, or 70%, or 80%, or 90%, oreven up to 100%, by weight of the layer, of cross-linked cellulosefibers (including the cross-linking agents).

Acquisition Layer

If a three-dimensional nonwoven material of the present disclosure isprovided as only the topsheet of an absorbent article, the ADS 250 maycomprise an acquisition layer 252. The acquisition layer may be disposedbetween the distribution layer 254 and the topsheet 224. In such aninstance, the acquisition layer 252 may be or may comprise a nonwovenmaterial, such as a hydrophilic SMS or SMMS material, comprising aspunbonded, a melt-blown and a further spunbonded layer or alternativelya carded staple fiber chemical-bonded nonwoven. The nonwoven materialmay be latex bonded.

Fastening System

The absorbent article may comprise a fastening system. The fasteningsystem may be used to provide lateral tensions about the circumferenceof the absorbent article to hold the absorbent article on the wearer asis typical for taped diapers. This fastening system may not be necessaryfor training pant articles since the waist region of these articles isalready bonded. The fastening system may comprise a fastener such astape tabs, hook and loop fastening components, interlocking fastenerssuch as tabs & slots, buckles, buttons, snaps, and/or hermaphroditicfastening components, although any other suitable fastening mechanismsare also within the scope of the present disclosure. A landing zone 244is normally provided on the garment-facing surface of the front waistregion 205 for the fastener to be releasably attached thereto.

Front and Rear Ears

The absorbent article may comprise front ears 246 and rear ears 240. Theears may be an integral part of the chassis, such as formed from thetopsheet 224 and/or backsheet 226 as side panels. Alternatively, asrepresented on FIG. 28, the ears may be separate elements attached bygluing, heat embossing, and/or pressure bonding. The rear ears 240 maybe stretchable to facilitate the attachment of the tabs 242 to thelanding zone 244 and maintain the taped diapers in place around thewearer's waist. The rear ears 240 may also be elastic or extensible toprovide a more comfortable and contouring fit by initially conformablyfitting the absorbent article to the wearer and sustaining this fitthroughout the time of wear well past when absorbent article has beenloaded with fluids or other bodily exudates since the elasticized earsallow the sides of the absorbent article to expand and contract.

Elastic Waist Feature

The absorbent article 220 may also comprise at least one elastic waistfeature (not represented) that helps to provide improved fit andcontainment. The elastic waist feature is generally intended toelastically expand and contract to dynamically fit the wearer's waist.The elastic waist feature may extend at least longitudinally outwardlyfrom at least one waist edge of the absorbent core 228 and generallyforms at least a portion of the end edge of the absorbent article.Disposable diapers may be constructed so as to have two elastic waistfeatures, one positioned in the front waist region and one positioned inthe rear waist region.

Sanitary Napkin

The three-dimensional nonwoven materials of the present disclosure mayform a portion of a sanitary napkin, for instance, a portion of, or allof, a topsheet, or portion of, or all of, a topsheet and acquisitionlayer (or secondary topsheet). In other instances, the three-dimensionalnonwoven materials may form a strip or patch placed on the topsheet ofthe sanitary napkin. An example sanitary napkin 500 is disclosed in FIG.36. The sanitary napkin 500 may comprise a liquid permeable topsheet514, a liquid impermeable, or substantially liquid impermeable,backsheet 516, and an absorbent core 508. The absorbent core 508 mayhave any or all of the features described herein with respect to theabsorbent cores 228 and, in some forms, may have a secondary topsheet(acquisition layer or system) instead of the acquisition-distributionsystem disclosed above. The sanitary napkin 500 may also comprise wings520 extending outwardly with respect to a longitudinal axis 580 of thesanitary napkin 500. The sanitary napkin 500 may also comprise a lateralaxis 590. The wings 520 may be joined to the topsheet 514, the backsheet516, and/or the absorbent core 508. The sanitary napkin 500 may alsocomprise a front edge 522, a rear edge 524 longitudinally opposing thefront edge 522, a first side edge 526, and a second side edge 528longitudinally opposing the first side edge 526. The longitudinal axis580 may extend from a midpoint of the front edge 522 to a midpoint ofthe rear edge 524. The lateral axis 590 may extend from a midpoint ofthe first side edge 526 to a midpoint of the second side edge 528. Thesanitary napkin 500 may also be provided with additional featurescommonly found in sanitary napkins as is generally known in the art,such as a secondary topsheet 519, for example.

Packages

Absorbent articles comprising airfelt-free cores and the high loft,three-dimensional nonwoven materials of the present disclosure may beplaced into packages. The packages may comprise polymeric films and/orother materials. Graphics and/or indicia relating to properties of theabsorbent articles may be formed on, printed on, positioned on, and/orplaced on outer portions of the packages. Each package may comprise aplurality of absorbent articles. The absorbent articles may be packedunder compression so as to reduce the size of the packages, while stillproviding an adequate amount of absorbent articles per package. Bypackaging the absorbent articles under compression, caregivers caneasily handle and store the packages, while also providing distributionsavings to manufacturers owing to the size of the packages.

As discussed above, one of the unexpected benefits of the absorbentarticles of the present disclosure having airfelt-free cores and thenonwoven materials as a topsheet and/or a topsheet and acquisition layerlaminate is cost savings to the consumer and the manufacturer owing toreduced stack height. Accordingly, packages of the absorbent articles ofthe present disclosure may have an In-Bag Stack Height of less thanabout 100 mm, less than about 95 mm, less than about 90 mm, less thanabout 85 mm, less than about 85 mm, but greater than about 75 mm, lessthan about 80 mm, less than about 78 mm, less than about 76 mm, or lessthan about 74 mm, specifically reciting all 0.1 mm increments within thespecified ranges and all ranges formed therein or thereby, according tothe In-Bag Stack Height Test described herein. Alternatively, packagesof the absorbent articles of the present disclosure may have an In-BagStack Height of from about 70 mm to about 100 mm, from about 70 mm toabout 95 mm, from about 72 mm to about 85 mm, from about 72 mm to about80 mm, or from about 74 mm to about 78 mm, specifically reciting all 0.1mm increments within the specified ranges and all ranges formed thereinor thereby, according to the In-Back Stack Height Test described herein.

FIG. 37 illustrates an example package 1000 comprising a plurality ofabsorbent articles 1004. The package 1000 defines an interior space 1002in which the plurality of absorbent articles 1004 are situated. Theplurality of absorbent articles 1004 are arranged in one or more stacks1006.

EXAMPLES Comparative Example 1

In Comparative Example 1, the material is a composite of two materialsglued together using H. B. Fuller of St. Paul, Minn., U.S.A. D3166ZP hotmelt adhesive applied in a spiral pattern at a 1 gsm add on level. Thecomposite material is processed through a nip formed by one of TheProcter & Gamble Company's SELF rolls and a ring roll as described inU.S. Pat. No. 7,410,683 B2, Curro, et al., at 25 feet/minute (fpm) (7.6meters per minute) and 0.135″ (3.43 mm) DOE. The material layer incontact with the SELF roll is a 20 gsm spunbond nonwoven produced byFitesa of Simpsonville, S.C., U.S.A. Such a material is described inFitesa's U.S. patent application Ser. No. 14/206,699 entitled“Extensible Nonwoven Fabric” and is comprised of 2.5 denier fiberscomprising a blend of PP and PE fibers. The material layer in contactwith the ring roll is a 43 gsm spunbond nonwoven produced by Reicofil ofTroisdorf, Germany, comprised of 7 denier co-PET/PET tipped-trilobalbicomponent fibers.

Example 1 Single Layer

In Example 1, the material is a 50 grams/m² (gsm) PE/PP sheath/corebicomponent spunbond nonwoven from Fitesa. It is processed at 25 fpm(7.6 meters per minute) speed at 0.155 inch (3.94 mm) depth ofengagement (DOE) through male/female tooling (forming members). Theteeth on the male tool have a rounded diamond shape like that shown inFIG. 21, with vertical sidewalls and a radiused or rounded edge at thetransition between the top and the sidewalls of the tooth. The teeth are0.186 inch (4.72 mm) long and 0.125 inch (3.18 mm) wide with a CDspacing of 0.150 inch (3.81 mm) and an MD spacing of 0.346 inch (8.79mm). The recesses in the mating female roll also have a rounded diamondshape, similar to that of the male roll, with a clearance between therolls of 0.032-0.063 inch (0.813-1.6 mm), varying slightly around theperimeter of the recess.

Example 2 Two layers

In Example 2, the material is a composite of two materials gluedtogether using the same hot melt adhesive applied in a spiral pattern asdescribed in Comparative Example 1. It is processed through themale/female tooling described in Example 1, at 800 feet per minute (fpm)(24.4 meters per minute) and 0.155 inch (3.94 mm) DOE. The materiallayer in contact with the male roll is the 20 gsm spunbond nonwovenproduced by Fitesa comprised of 2.5 denier fibers with a blend of PP andPE described in Comparative Example 1. The material layer in contactwith the female roll is a 60 gsm through-air bonded carded nonwovenproduced by Beijing Dayuan Non-Woven Fabric Co, LTD of Beijing, China,comprised of 5 denier PE/PET sheath/core bicomponent fibers.

Example 3 Two layers

In Example 3, the material is a composite of two materials gluedtogether using the same hot melt adhesive applied in a spiral pattern asdescribed in Comparative Example 1. It is processed through themale/female tooling described in Example 1, at 800 fpm and 0.155 inch(3.94 mm) DOE. The material layer in contact with the male roll is a 20gsm spunbond nonwoven produced by Fitesa comprised of 2.5 denier fiberswith a blend of PP and PE described in Example 2. The material layer incontact with the female roll is an 86 gsm spunbond nonwoven produced byReicofil comprised of 7 denier co-PET/PET tipped-trilobal bicomponentfibers.

The samples are compressed according to the Accelerated CompressionMethod, with a 7 kPa weight). The pre-compression caliper and thepost-compression caliper of the samples are measured following theAccelerated Compression Method. The dimensions of the protrusions andopenings are measured using a microscope at 20× magnification. Theexterior dimensions of the cap are measured from a perspective view withthe protrusions facing up, like that shown in FIG. 5. The protrusiondepth and the interior cap width is measured from the cross-section ofthe material like that shown in FIG. 11.

Ratio of Cap Base Cap width- Measured Opening Base Width- Cap CapInterior First Layer Second Layer Before or After Caliper at ProtrusionWidth Opening Interior Width- Length- to Base (Contacts (ContactsCompression 2.1 kPa Depth (W₀) Length (W_(I)) Exterior Exterior OpeningExample Male Tool) Female Tool) (7 kPa) (mm) (mm) (mm) (mm) (mm) (mm)(mm) Width Comp. 20 gsm 43 gsm co- Before 1.2 1.1 0.5 4.7 <0.1* 1.5 4.6— Ex. 1 Spunbond PET/PET Compression (Tuft) (Tuft) (Tuft) (Tuft) PE/PPBlend Spunbond After 0.7 0.3 0* 4.7 0* 0.7 4.0 — Compression (opening(opening was was closed) closed) Ex. 1 50 gsm None Before 0.48 1.3 1.53.3 1.7 2.4 4.2 1.1 PE/PP Bico Compression Spunbond After 0.39 0.4 1.73.0 2.1 2.9 4.3 1.2 Compression Ex. 2 20 gsm 60 gsm PET Before 1.6 1.91.9 3.5 2.4 3.2 4.5 1.3 Spunbond Carded Compression PE/PP BlendThrough-air After 0.88 0.5 1.6 3.3 1.8 2.7 4.4 1.1 Bonded CompressionEx. 3 20 gsm 86 gsm co- Before 2.0 1.9 1.8 3.8 2.2 3.8 4.8 1.2 SpunbondPET/PET Compression PE/PP Blend Spunbond After 1.3 0.7 1.5 3.6 2.5 3.75.2 1.7 Compression *Difficult to measure because measurement was sosmall

Test Methods:

A. Accelerated Compression Method.

-   -   1. Cut 10 samples of the specimen to be tested and 11 pieces of        a paper towel into a 3 inch×3 inch (7.6 cm×7.6 cm) square.    -   2. Measure the caliper of each of the 10 specimens at 2.1 kPa        and a dwell time of 2 seconds using a Thwing-Albert ProGage        Thickness Tester or equivalent with a 50-60 millimeter diameter        circular foot. Record the pre-compression caliper to the nearest        0.01 mm.    -   3. Alternate the layers of the specimens to be tested with the        pieces of paper towel, starting and ending with the paper        towels. The choice of paper towel does not matter and is present        to prevent “nesting” of the protrusions in the deformed samples.        The samples should be oriented so the edges of each of the        specimens and each of the paper towels are relatively aligned,        and the protrusions in the specimens are all oriented the same        direction.    -   4. Place the stack of samples into a 40° C. oven and place a        weight on top of the stack. The weight must be larger than the        foot of the thickness tester. To simulate high pressures or low        in-bag stack heights, apply 35 kPa (e.g. 17.5 kg weight over a        70×70 mm area). To simulate low pressures or high in-bag stack        heights, apply 7 kPa (e.g. 3.5 kg weight over a 70×70 mm area).    -   5. Leave the samples in the oven for 15 hours. After the time        period has elapsed, remove the weight from the samples and        remove the samples from the oven.    -   6. Within 30 minutes of removing the samples from the oven,        measure the post-compression caliper as directed in step 2        above, making sure to maintain the same order in which the        pre-compression caliper was recorded. Record the        post-compression caliper of each of the 10 specimens to the        nearest 0.01 mm.    -   7. Let the samples rest at 23±2° C. and at 50±2% relative        humidity for 24 hours without any weight on them.

8. After 24 hours, measure the post-recovery caliper of each of the 10specimens as directed in step 2 above, making sure to maintain the sameorder in which the pre-compression and post-compression calipers wererecorded. Record the post-recovery caliper of each of the 10 specimensto the nearest 0.01 mm. Calculate the amount of caliper recovery bysubtracting the post-compression caliper from the post-recovery caliperand record to the nearest 0.01 mm.

-   -   9. If desired, an average of the 10 specimens can be calculated        for the pre-compression, post-compression and post-recovery        calipers.

B. Tensile Method

The MD and CD tensile properties are measured using method WSP 110.4(05) Option B, with a 50 mm sample width, 60 mm gauge length, and 60mm/min rate of extension. Note that the gauge length, rate of extensionand resultant strain rate are different from that specified within themethod.

C. In-Bag Stack Height Test

The in-bag stack height of a package of absorbent articles is determinedas follows:

Equipment

A thickness tester with a flat, rigid horizontal sliding plate is used.The thickness tester is configured so that the horizontal sliding platemoves freely in a vertical direction with the horizontal sliding platealways maintained in a horizontal orientation directly above a flat,rigid horizontal base plate. The thickness tester includes a suitabledevice for measuring the gap between the horizontal sliding plate andthe horizontal base plate to within ±0.5 mm. The horizontal slidingplate and the horizontal base plate are larger than the surface of theabsorbent article package that contacts each plate, i.e. each plateextends past the contact surface of the absorbent article package in alldirections. The horizontal sliding plate exerts a downward force of850±1 gram-force (8.34 N) on the absorbent article package, which may beachieved by placing a suitable weight on the center of thenon-package-contacting top surface of the horizontal sliding plate sothat the total mass of the sliding plate plus added weight is 850±1grams.

Test Procedure

Absorbent article packages are equilibrated at 23±2° C. and 50±5%relative humidity prior to measurement.

The horizontal sliding plate is raised and an absorbent article packageis placed centrally under the horizontal sliding plate in such a waythat the absorbent articles within the package are in a horizontalorientation (see FIG. 37). Any handle or other packaging feature on thesurfaces of the package that would contact either of the plates isfolded flat against the surface of the package so as to minimize theirimpact on the measurement. The horizontal sliding plate is loweredslowly until it contacts the top surface of the package and thenreleased. The gap between the horizontal plates is measured to within±0.5 mm ten seconds after releasing the horizontal sliding plate. Fiveidentical packages (same size packages and same absorbent articlescounts) are measured and the arithmetic mean is reported as the packagewidth. The “In-Bag Stack Height”=(package width/absorbent article countper stack)×10 is calculated and reported to within ±0.5 mm.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “90°” is intended to mean“about 90°”.

It should be understood that every maximum numerical limitation giventhroughout this specification includes every lower numerical limitation,as if such lower numerical limitations were expressly written herein.Every minimum numerical limitation given throughout this specificationwill include every higher numerical limitation, as if such highernumerical limitations were expressly written herein. Every numericalrange given throughout this specification will include every narrowernumerical range that falls within such broader numerical range, as ifsuch narrower numerical ranges were all expressly written herein.

All documents cited in the Detailed Description are, in relevant part,incorporated herein by reference; the citation of any document is not tobe construed as an admission that it is prior art with respect to thepresent disclosure. To the extent that any meaning or definition of aterm in this written document conflicts with any meaning or definitionof the term in a document incorporated by reference, the meaning ordefinition assigned to the term in this written document shall govern.

While particular embodiments of the present disclosure have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. An absorbent article comprising: a liquidpervious nonwoven material having a first surface and a second surface,the nonwoven material comprising a plurality of fibers, wherein thenonwoven material comprises a generally planar first region and aplurality of discrete integral second regions that comprise deformationsforming protrusions extending outward from the first surface of thenonwoven material and openings in the second surface of the nonwovenmaterial, the protrusions being formed from the fibers, wherein at leastsome of the protrusions have an exterior width, and two ends that definea length of the protrusion therebetween, and the at least some of theprotrusions comprise a base proximate the first surface of the nonwovenmaterial, an opposed distal end extending outward in the Z-directionfrom the base, side walls between the base and the distal end of theprotrusion, and a cap comprising at least a portion of the side wallsand the distal end of the protrusion, wherein the side walls haveinterior surfaces, and wherein the exterior width of the protrusionvaries along the length of the protrusion when the nonwoven material isviewed from the Z-direction; a liquid impermeable material; and anabsorbent core positioned intermediate the nonwoven material and theliquid impermeable material, wherein the absorbent core comprises anabsorbent material, and wherein the absorbent material comprises atleast 90% superabsorbent polymers by weight of the absorbent materialand a hotmelt adhesive.
 2. The absorbent article of claim 1, wherein theinterior surfaces of the side walls define a base opening at the base ofthe protrusion, wherein the cap has a portion with a maximum interiorwidth, wherein the base opening has a width, and wherein the maximuminterior width of the cap of the protrusion is greater than the width ofthe base opening.
 3. The absorbent article of claim 1, wherein a channelis formed in the absorbent material.
 4. The absorbent article of claim3, wherein a second channel is formed in the absorbent material.
 5. Theabsorbent article of claim 1, wherein the absorbent material comprisesat least 99% superabsorbent polymers by weight of the absorbentmaterial.
 6. The absorbent article of claim 1, wherein the absorbentmaterial is substantially free of cellulosic, natural, or syntheticfibers.
 7. The absorbent article of claim 1, wherein the at least someprotrusions of the nonwoven material have a middle between their ends,and wherein the at least some protrusions are wider in the middle thanthe ends.
 8. The absorbent article of claim 1, wherein the at least someof the protrusions of the nonwoven material have a non-circular planview configuration.
 9. The absorbent article of claim 1, whereinmultiple fibers of the nonwoven material extend from the base ofprotrusion to the distal end of the protrusion, and contribute to form aportion of the sides and the cap of the protrusion, and wherein thefibers at least substantially surround the sides of the protrusion. 10.The absorbent article of claim 1, wherein the base opening has a minimumwidth measured at the center of the base opening, and wherein theminimum width is at least about 0.5 mm.
 11. The absorbent article ofclaim 1, wherein the nonwoven material comprises two or more layers ofnonwoven material.
 12. The absorbent article of claim 11, wherein thefirst layer comprises a liquid pervious topsheet, and wherein the secondlayer comprises an acquisition layer.
 13. The absorbent article of claim1, wherein the two or more layers are nested within at least one of theprotrusions.
 14. The absorbent article of claim 1, wherein the nonwovenmaterial comprises a single layer, and wherein the single layercomprises a liquid permeable topsheet.
 15. The absorbent article ofclaim 13, wherein the absorbent material comprises at least 95%superabsorbent polymers by weight of the absorbent material, and whereinthe absorbent material is substantially free of cellulosic, natural orsynthetic fibers.
 16. The absorbent article of claim 12, comprising acarrier layer for supporting a distribution material, wherein thecarrier layer is in a facing relationship with the acquisition layer.17. A package comprising a plurality of the absorbent articles of claim1, wherein the package has an in-bag stack height of less than about 85mm, according to the In-Back Stack Height Test herein.
 18. An absorbentarticle comprising: a liquid pervious nonwoven material having a firstsurface and a second surface, the nonwoven material comprising aplurality of fibers, wherein the nonwoven material comprises a generallyplanar first region and a plurality of discrete integral second regionsthat comprise deformations forming protrusions extending outward fromthe first surface of the nonwoven material and openings in the secondsurface of the nonwoven material, the protrusions being formed from thefibers, wherein at least some of the protrusions have an exterior width,and two ends that define a length of the protrusion therebetween, andthe at least some protrusions comprise a base proximate the firstsurface of the nonwoven material, an opposed distal end extendingoutward in the Z-direction from the base, side walls between the baseand the distal end of the protrusion, and a cap comprising at least aportion of the side walls and the distal end of the protrusion, whereinthe side walls have interior surfaces, wherein the interior surfaces ofthe side walls define a base opening at the base of the protrusion,wherein the cap has a portion with a maximum interior width, wherein thebase opening has a width, and wherein the maximum interior width of thecap of the protrusion is greater than the width of the base opening; aliquid impermeable material; and an absorbent core positionedintermediate the nonwoven material and the liquid impermeable material,wherein the absorbent core comprises an absorbent material, and whereinthe absorbent material comprises at least 85% superabsorbent polymers byweight of the absorbent material and a hotmelt adhesive.
 19. Theabsorbent article of claim 18, wherein the exterior width of theprotrusion varies along the length of the protrusion when the nonwovenmaterial is viewed from the z-direction.
 20. The absorbent article ofclaim 18, wherein the absorbent material comprises at least 99%superabsorbent polymers by weight of the absorbent material, and whereinthe absorbent material is substantially free of cellulosic, natural orsynthetic fibers.
 21. The absorbent article of claim 18, wherein thenonwoven material comprises a plurality of layers, and wherein at leasttwo of the plurality of layers are nested within the protrusion, andwherein the protrusion is substantially hollow and forms a bulbousshape.
 22. The absorbent article of claim 21, wherein a first layercomprises a liquid permeable topsheet, and wherein a second layercomprises a liquid permeable acquisition material.
 23. The absorbentarticle of claim 22, comprising a carrier layer and a distribution layerapplied to the carrier layer, wherein the carrier layer is in a facingrelationship with the liquid permeable acquisition material.
 24. Apackage comprising a plurality of the absorbent articles of claim 18,wherein the package has an in-bag stack height of less than about 90 mm,according to the In-Back Stack Height Test herein.
 25. A packagecomprising: a plurality of absorbent articles, wherein at least some ofthe absorbent articles comprise: a liquid pervious nonwoven materialhaving a first surface and a second surface, the nonwoven materialcomprising a plurality of fibers, wherein the nonwoven materialcomprises a generally planar first region and a plurality of discreteintegral second regions that comprise deformations forming protrusionsextending outward from the first surface of the nonwoven material andopenings in the second surface of the nonwoven material, the protrusionsbeing formed from the fibers, wherein at least some of the protrusionshave an exterior width, and two ends that define a length of theprotrusion therebetween, and the at least some protrusions comprise abase proximate the first surface of the nonwoven material, an opposeddistal end extending outward in the Z-direction from the base, sidewalls between the base and the distal end of the protrusion, and a capcomprising at least a portion of the side walls and the distal end ofthe protrusion, wherein the side walls have interior surfaces, whereinthe interior surfaces of the side walls define a base opening at thebase of the protrusion, wherein the cap has a portion with a maximuminterior width, wherein the base opening has a width, and wherein themaximum interior width of the cap of the protrusion is greater than thewidth of the base opening; a liquid impermeable material; and anabsorbent core positioned intermediate the liquid permeable nonwovenmaterial and the liquid impermeable material, wherein the absorbent corecomprises an absorbent material, wherein the absorbent materialcomprises at least 85% superabsorbent polymers by weight of theabsorbent material and a hotmelt adhesive; wherein the package has anin-bag stack height of less than about 100 mm, but greater than about 70mm, according to the In-Back Stack Height Test herein.
 26. The packageof claim 25, wherein the nonwoven material comprises a topsheet and anacquisition layer.